Electrical Connection Box Bonder Cap Nesting
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Solution Overview
Problem
The increasing number of electronic components in electrical connection boxes on vehicles leads to a larger size, making it difficult to accommodate bonder caps efficiently, which complicates miniaturization and prevents effective protection against cap detachment or falling.
Innovation Solution
An electrical connection box design featuring a housing with an electric wire bundle holder and a lower cover having a deep bottom part with a drainage hole and a shallow bottom part with an inclined surface, allowing the bonder cap to be inserted and maintained securely, thus preventing detachment and contributing to miniaturization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of electronic components in the electrical connection box is increased, then the functionality and protection capability are improved, but the size of the electrical connection box increases, making miniaturization difficult
Solution Approach 1:
The bonder cap is nested within the electrical connection box by utilizing the space formed by the inclined surface and the holder. The bonder cap is positioned in the space between the holder and the lower cover, effectively nesting it within the existing structure without requiring additional external space.
Solution Approach 2:
The inclined surface creates a three-dimensional space that utilizes the vertical dimension and angular orientation to accommodate the bonder cap. By forming the lower cover with an inclined surface rather than a flat surface, the design creates additional accommodation space in the vertical dimension without increasing the horizontal footprint of the electrical connection box.
2Reliability
If conventional bonder cap accommodation methods are used (coupling portion with regulator or covering attached to frame), then the bonder cap is protected from falling, but the structure becomes complicated, preventing miniaturization
Solution Approach 1:
The function of preventing bonder cap detachment is merged into the existing lower cover structure. The inclined surface and holder work together as an integrated system to secure the bonder cap, eliminating the need for separate regulators or coverings that would add structural complexity.
Solution Approach 2:
The inclined surface of the lower cover automatically prevents the bonder cap from falling by utilizing gravity and geometry. The bonder cap is passively secured by the inclined surface without requiring active regulation mechanisms or additional fastening components, achieving self-service protection.
3Volume of stationary object
If the electrical connection box is miniaturized, then the space efficiency is improved, but the accommodation space for bonder caps becomes insufficient
Solution Approach 1:
The inclined surface creates three-dimensional accommodation space that efficiently utilizes the vertical dimension. By orienting the surface at an angle rather than horizontally, the design maximizes the use of vertical space within the miniaturized box, providing sufficient bonder cap accommodation without increasing the overall horizontal footprint.
Solution Approach 2:
The lower cover is designed with localized differentiating features: an inclined surface in the region where bonder caps need accommodation, and a drainage hole in specific locations. This localized quality approach provides targeted accommodation space for bonder caps in specific areas without requiring the entire box to be larger.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design efficiently accommodates electric wire bundles covered with bonder caps, preventing cap detachment and allowing for a more compact structure, enhancing drainage and accommodation efficiency while maintaining the integrity of the wire harness.
Implementation Method 1
a shallow bottom part located above the deep bottom part below the electric wire bundle holder, with the shallow bottom part being formed to include an inclined surface inclined downward toward the deep bottom part, and a state where the bonder cap is inserted into the electric wire bundle holder is maintained on the inclined surface of the shallow bottom part on the lower cover
Data Source
AI summary
An electrical connection box can include a housing and a lower cover that closes a lower part of the housing in which the housing includes an electric wire bundle holder whose lower side open so as to be able to allow insertion of a bonder cap of an electric wire bundle in a state where the electric wire bundle is covered with the bonder cap. The lower cover includes a deep bottom part having a drainage hole. A shallow bottom part can be located above the deep bottom part below the electric wire bundle holder, with the shallow bottom part being formed to include an inclined surface inclined downward toward the deep bottom part, and a state where the bonder cap is inserted into the electric wire bundle holder is maintained on the inclined surface of the shallow bottom part on the lower cover.