Electrical Connection Box Cover Member Deformation Control

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Solution Overview

Problem

Conventional electrical connection boxes suffer from excessive deformation of the cover member due to external forces during transportation, which can lead to structural issues and potential damage.

Innovation Solution

The electrical connection box design incorporates a cover member with locking, restriction, and rigid pieces that fit securely into corresponding reception parts in the casing, providing orthogonal support and reducing deformation through a wedge-shaped rigid part configuration, which helps distribute and absorb external forces effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the cover member is made with simple structure for ease of manufacture, then manufacturing cost is reduced, but the cover member becomes susceptible to excessive deformation under external forces

Engineering Contradiction:

Improveease of manufactureVSAvoidresistance to deformation

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The cover member is divided into multiple functional segments: locking pieces for securing to the casing, restriction pieces for limiting movement, and rigid pieces for providing structural support. Each segment performs a specific function to collectively prevent deformation while maintaining manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the cover member have different structural properties - the locking pieces have engagement features for secure attachment, the restriction pieces have geometry designed to limit movement in specific directions, and the rigid pieces have enhanced stiffness. This local differentiation provides targeted reinforcement where needed without unnecessarily complicating the entire structure.

Inventive Principle:

Principle #3Local quality

2Strength

If additional locking mechanisms are added to prevent deformation, then structural integrity is improved, but device complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidcomplexity of locking mechanisms

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The locking, restriction, and rigid support functions are merged into a single integrated cover member structure. The locking pieces, restriction pieces, and rigid pieces are all part of the same cover member, eliminating the need for separate locking mechanisms and reducing overall device complexity while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cover member serves multiple functions simultaneously: it provides structural support, secures the wiring member holding part, limits movement through restriction pieces, and prevents deformation. This multi-functionality reduces the need for additional specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If the cover member is designed with adequate support structures to prevent deformation, then structural integrity is improved, but the fitting process becomes more complex

Engineering Contradiction:

Improvestructural integrityVSAvoidease of fitting

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The locking pieces, restriction pieces, and rigid pieces are pre-configured in the cover member with specific geometries and orientations. The locking pieces have engagement features that automatically align with corresponding features on the casing, and the restriction pieces are positioned to naturally limit movement in the desired directions, simplifying the fitting process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of adding complex external support structures that would complicate fitting, the support and locking functions are inverted and integrated directly into the cover member itself. The cover member's own structure provides the reinforcement and securing mechanisms, making the fitting process more straightforward.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS11462896B2Electrical connection box

Publication Date: 2022.10.04 YAZAKI CORP

AI summary

An electrical connection box includes a casing and a cover member. The cover member includes: a cover-member main body; a restriction piece arranged along an arrangement direction with respect to a pair of locking pieces; and a rigid part that is disposed with a space provided with respect to the cover-member main body in an orthogonal direction and is extended toward the orthogonal direction. The casing includes: a pair of restriction reception parts opposing to respective ends in the arrangement direction of a pair of the restriction pieces in a state in which the cover member is fitted to the casing; and a rigid reception part having a rigid-reception-part projecting wall part located between the rigid part and the cover-member main body in a state in which the rigid part is inserted and the cover member is fitted to the casing.