Electric Connection Box Regulating Portion Wire Deformation

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Solution Overview

Problem

Existing electric connection boxes face issues with electric wire deformation and water ingress due to the gap between the housing and the wire, which affects the wire's stability and waterproofing when attached to a vehicle body.

Innovation Solution

An electric connection box design featuring a housing with a side cover having an inclined wall, a side space portion, and a regulating portion that projects along the inclined direction to prevent wire deformation and water entry, where the electric wire is bent and crimped to a terminal, and a regulating portion is used to maintain the wire's position and prevent water from entering the gap.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the electric wire is fastened to the stud bolt by making the stud bolt pass through the through-hole of the terminal and screwing a nut to the stud bolt, then the electric wire supplies power from the outside of the housing to the electric components in the internal space portion, but the electric wire may be deformed to approach the housing during a rotation movement of the nut caused by screwing the nut to the bolt in a state where the nut comes into contact with the terminal

Engineering Contradiction:

Improvepower supply reliabilityVSAvoidwire position stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent applies preliminary action by pre-forming the electric wire to extend downward and incline in a direction separating from the housing before fastening, and by pre-positioning the regulating portion to guide the wire's final position. This preliminary configuration prevents deformation during the nut rotation process, as the wire is already oriented to avoid contact with the housing during assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The regulating portion acts as an intermediary element between the electric wire and the housing. It guides and constrains the wire's position during fastening, preventing the wire from deforming toward the housing while the nut is being screwed. This intermediary structure mediates the conflict between securing the wire firmly and preventing its deformation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the electric wire which has been previously extended downward in the side space portion and been inclined in a direction separating from the housing is fastened to the stud bolt, then the electric wire is securely attached, but a gap is formed between the outer peripheral surface of the housing and the electric wire

Engineering Contradiction:

Improvewire fastening easeVSAvoidliquid ingress risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The regulating portion serves as an intermediary structure that fills and seals the gap between the housing's outer peripheral surface and the electric wire. By positioning itself in this gap, it prevents liquid from entering while maintaining the wire's inclined configuration that separates it from the housing, thus resolving the contradiction between ease of fastening and liquid protection.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The regulating portion functions as a flexible sealing element that can adapt to the gap between the housing and wire. It creates a barrier against liquid ingress while allowing the wire to maintain its operational position and movement freedom, effectively sealing the interface without restricting the wire's function.

Inventive Principle:

Principle #30Flexible shells and thin films

3Device complexity

If the electric wire extends from the internal space portion where the stud bolt is provided to the side space portion on the outer peripheral side of the housing, passes through the side space portion, and is routed to the outside of the housing through the opening, then the wire routing is simplified, but the wire is exposed to potential liquid entry paths

Engineering Contradiction:

Improvewire routing complexityVSAvoidliquid exposure risk

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The regulating portion acts as a protective intermediary along the wire's routing path from the internal space portion through the side space portion to the outside. It creates a sealed pathway that maintains the simplified routing configuration while blocking liquid entry at critical interface points, thus protecting the wire without adding routing complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10131297B1Electric connection box and wire harness

Publication Date: 2018.11.20 YAZAKI CORP

AI summary

In an electric connection box and a wire harness, a side cover is attached to an outer peripheral surface of a housing, and the housing and the side cover form a side space portion. An electric wire extends from an internal space portion to the side space portion and is routed to the outside of the housing through the side space portion. In the electric wire, an electric wire main body is formed along an inclined direction of an inclined wall of the side cover. A regulating portion is formed along the inclined direction of the inclined wall in the housing in the side space portion. A gap between the electric wire and the housing is filled with the regulating portion. In the side space portion, the electric wire main body is positioned between the inclined wall of the side cover and the regulating portion.