Angled Flap Junction Box for Secure Cable Retention
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Solution Overview
Problem
Existing electrical junction boxes can cause stress on electrical terminals over time, leading to potential damage or hazards due to cables being pushed further into the box, which can result in a loose or damaged connection.
Innovation Solution
A junction box design featuring hingedly connected lids with angled flaps that inhibit cable pushing and pulling, ensuring secure cable retention through a combination of outwardly and inwardly extending flaps, and optional features like cable ties and stepped inlets for accommodating different wire diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cables are allowed to enter the junction box freely through simple slots, then cable installation is easy, but cables can be pushed further into the box over time causing stress on terminals and potential damage
Solution Approach 1:
The patent applies preliminary anti-action by incorporating flaps that extend into the slot to prevent cables from being pushed further into the junction box. These flaps create a physical barrier that opposes the harmful movement of cables before damage can occur, while still allowing cables to be inserted during installation.
Solution Approach 2:
The inlet is segmented into multiple components including the slot, flaps, and cable retention structures. This segmentation allows each component to perform its specific function: the slot allows cable entry, while the flaps and retention structures prevent excessive insertion and secure the cable in place.
2Reliability
If cables are retained securely in the junction box, then connection reliability is improved, but cable installation and access become more difficult
Solution Approach 1:
The flaps are designed to be flexible and dynamic, allowing them to move during cable installation to accommodate cable entry, then return to their blocking position to prevent excessive insertion. This dynamic behavior enables the structure to adapt to different operational states without requiring complex mechanisms.
3Ease of manufacture
If the junction box has a fixed structure, then manufacturing is simple, but it cannot accommodate different cable sizes effectively
Solution Approach 1:
The patent employs parameter changes by designing flaps with varying angles and dimensions that can be adjusted to accommodate different cable sizes. The angled flaps create retention forces that adapt to different cable diameters while maintaining the same basic structural design.
Data Source
AI summary
A junction box has a main body defining an interior space and a lid hingedly connected to the main body for use in enclosing the interior space. The main body includes an inlet for allowing an end of electrical cable to be positioned with the interior space. The inlet is formed by a first pair of spaced flaps between which is defined a first slot into which the electrical cable is to be positioned and a second pair of spaced flaps between which is defined a second slot into which the electrical cable is to be positioned. Each of the first pair of flaps is arranged to extend outwardly from the defined first slot at an angle that is away from the interior space to provide a structure that will inhibit a pushing of the electrical cable further into the interior space. Each of the second pair of flaps is arranged to extend inwardly from the defined second slot at an angle towards the interior space to provide a structure that will inhibit a pulling of the electrical cable from the interior space.