Elastic Junction Box Cover Locking Mechanism for Vibration Noise Reduction
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Solution Overview
Problem
Conventional electric junction boxes on vehicles experience abnormal noise due to cover movement and separation caused by vibration, which affects smooth attachment and reliability.
Innovation Solution
A box main body design featuring a thin portion and tapered projection on one cover member that elastically deforms and separates from the other cover member when attached, preventing movement and reducing the force required for assembly, while avoiding bending of locking components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a moderate space is provided between the locking portion and locking receiving portion for smooth fitting, then the assembly process is facilitated, but the covers move and collide under vibration causing abnormal noise
Solution Approach 1:
The locking portion is designed with elastic deformation capability, transforming from a rigid static structure to a dynamic structure that can adapt during assembly and operation. The elastic portion deforms during assembly to enable smooth fitting, then maintains stable locking under vibration conditions.
Solution Approach 2:
The physical state of the locking portion changes from undeformed to elastically deformed during assembly. This parameter change allows the locking portion to accommodate the moderate space for smooth fitting while maintaining sufficient locking force to prevent cover movement under vibration.
2Reliability
If the covers are tightly attached to prevent movement, then abnormal noise is prevented, but the assembly process becomes difficult due to excessive force required
Solution Approach 1:
The elastic portion provides dynamic response during assembly, deforming under assembly force to reduce resistance, then recovering to provide stable locking. This dynamic behavior resolves the contradiction between easy assembly and secure attachment.
Solution Approach 2:
The elastic portion acts as a cushioning element that absorbs assembly force, preventing excessive force transmission during attachment. This beforehand cushioning facilitates smooth assembly while ensuring secure final attachment.
3Strength
If the locking portion is made rigid for strong locking, then attachment strength is improved, but the locking portion bends under vibration causing abnormal noise
Solution Approach 1:
The locking portion has non-uniform structure with different local properties: the elastic portion provides flexibility and deformation capability, while the locking tip maintains sufficient rigidity for strong locking. This local quality differentiation resolves the contradiction between strength and stability.
Solution Approach 2:
The locking portion transitions from a purely rigid structure to a dynamic structure with elastic deformation capability. This allows the locking portion to absorb vibration energy through elastic deformation rather than bending or breaking, maintaining both strength and stability.
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
The solution ensures smooth and secure attachment of cover members, preventing abnormal noise and accidental separation, and simplifies the assembly process by controlling the force needed for closure.
Implementation Method 1
a thin portion arranged in a wall of one cover member, the wall being overlapped with a wall of the other cover member; and a tapered portion projecting from a bottom surface of the thin portion of the one cover member toward the wall of the other cover member
Data Source
AI summary
A box main body which can smoothly attach cover members each other and prevent generation of abnormal noise is provided. An electric junction box has the box main body including two covers attached to each other and an electric power distribution unit. The box main body has two covers attached to each other. Furthermore, the box main body has a thin portion arranged in the inner wall of the upper cove, and a tapered portion projecting from a bottom surface of the thin portion toward the peripheral wall of the lower cover, and gradually tapering toward the peripheral wall of the lower cover.