Distribution Box Connector Sealing and Lid Locking Mechanism
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Solution Overview
Problem
Existing distribution box connectors face difficulties in inserting tapered castellations through cutouts due to axial seal compression resistance, making it hard to rotate the connector into tight engagement, and there is a need for a vibration-proof and tamper-resistant lid assembly with convenient mounting plate retention.
Innovation Solution
The solution involves a connector with tapered castellations that radially compress an annular seal upon rotation, ensuring a tight seal without initial resistance during insertion, and a two-part lid assembly with serrations and a hinged release mechanism for secure closure, preventing unauthorized access and rotation, along with a design for retaining a mounting plate within the distribution box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If axial seal compression is applied to ensure tight sealing, then sealing reliability is improved, but connector insertion difficulty increases
Solution Approach 1:
The connector is segmented into two functional zones: the front portion with castellations for mechanical engagement and insertion, and the rear portion with the annular seal for sealing. This segmentation allows the insertion and sealing functions to be decoupled, enabling easy insertion followed by reliable sealing upon rotation.
Solution Approach 2:
The connector is designed to be inserted into the port first, aligning the castellations with the cutouts, before the sealing action occurs. The rotation operation then simultaneously achieves both the sealing compression and the mechanical locking, performing the sealing action after insertion but as part of the same engagement process.
2Reliability
If tapered castellations are used to enable rotation and tight engagement, then connector locking reliability is improved, but seal compression resistance during insertion increases
Solution Approach 1:
The sealing function is separated from the locking function. The tapered castellations are responsible solely for the locking mechanism upon rotation, while the annular seal at the rear is responsible for sealing. This segmentation eliminates the conflict where the seal would otherwise resist insertion while the tapered castellations are being positioned.
Solution Approach 2:
The seal is positioned in a different spatial dimension (rear of the connector) away from the insertion path of the castellations. The seal engages with a corresponding surface on the port body in a location that does not interfere with the forward motion of the castellations during insertion, allowing independent optimization of both functions.
3Device complexity
If a single-part lid is used for closure, then device simplicity is improved, but vibration resistance and tamper-proof capability deteriorate
Solution Approach 1:
The lid is divided into an outer lid part that provides structural support and screw-threaded engagement with the box, and an inner lid part that provides the sealing surface and tamper-resistant features. This segmentation allows each part to be optimized for its specific function while working together to achieve both simplicity and reliability.
Solution Approach 2:
The lid assembly combines two distinct components with different functional properties: the outer lid part with mechanical engagement features and the inner lid part with sealing and anti-tamper features. This composite structure achieves superior performance in vibration resistance and tamper-proof capability while maintaining relative simplicity through modular design.
4Strength
If screw-threaded lid engagement is used to secure the lid, then lid attachment strength is improved, but ease of operation deteriorates due to potential over-tightening or loosening
Solution Approach 1:
The serrated interaction between the outer lid part and inner lid part provides mechanical feedback during tightening. The serrations engage in a controlled manner that gives tactile feedback to the operator, preventing over-tightening and ensuring proper engagement without requiring precise torque control.
Solution Approach 2:
The screw-threaded engagement provides gradual adjustment capability, allowing the lid to be tightened to the appropriate strength level. The threaded mechanism converts rotational motion into linear engagement, enabling controlled application of clamping force that achieves strong attachment while maintaining operational control.
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 allows for easy and secure attachment of conduits with radial seal compression, provides vibration-proof and tamper-resistant lid engagement, and facilitates convenient mounting plate retention within the distribution box assembly.
Implementation Method 1
an inner annular surface of the opening forward of its inwardly radially extending wall being tapered so that as rotation occurs and the connector is urged towards the opening an annular seal carried by the connector is radially compressed so as tightly to seal between the connector and the body
Data Source
Figure 1~4
Figure 5~11
Figure 12~14
AI summary
A distribution box (10) has a lid (11) and connectors (12; 13; 51) which can be engaged at ports (16) in the side wall of the box. The ports (16) each have cut-outs (20) to receive complementary castellations (29) on an annular end wall of each connector, each castellation (29) being tapered on its rear face, so that when a connector is pushed into a port and rotated, the connector is tightly drawn into engagement at the port, the leading surface of which is tapered so that an 0-ring seal (27) is radially compressed. The lid (11) is formed by outer and inner lid parts (34:35) and serrations (46) around outer periphery of the inner lid part (35) are engaged by serrations on an inner portion of the outer lid port (34) at which a finger (39) is disposed, to form a releasable lock between the parts. Means can be provided to prevent unauthorised release of the finger and ribs (23) of the body of box (10) can be engaged by corresponding recesses around the inner lid part (35) to lock the inner lid part against rotation relative to the box (10). A mounting plate (49) can be retained in the box (110) against removal, by virtue of the extent through a port of a connector (12; 13; 51), or by screws in a selected spaced aligned peg pair (51, 52; 53, 54).