Electrical Connection Box Waterproofing via Nested Covers

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Solution Overview

Problem

Conventional electrical connection boxes lack effective waterproofing, particularly at the lower portion, which can lead to water ingress and potential damage to electronic components.

Innovation Solution

The design incorporates a frame with a tubular inner and outer wall, a lower cover, and an inner cover with a cylindrical portion and rib structure, creating a water storage area between the inner and lower covers to guide and store entering water, thereby preventing it from reaching the electronic components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If water enters from the lower portion of the electrical connection box, then the electronic components are exposed to water damage, but adding waterproof structures increases device complexity

Engineering Contradiction:

ImprovewaterproofnessVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The electrical connection box is segmented into multiple functional layers: outer cover, lower cover with water storage chamber, frame with inner wall, and inner cover. This segmentation allows water to be captured and isolated in the lower water storage chamber, preventing it from reaching the electronic components housed in the upper accommodation space.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs nested structures where the inner wall is surrounded by the outer wall, the inner cover is disposed inside the lower cover, and the water storage chamber is nested within the lower cover. This nested arrangement creates multiple protective barriers against water ingress while maintaining a compact overall structure.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Object-affected harmful factors

If a waterproof structure is added to protect electronic components, then protection is improved, but the device complexity increases

Engineering Contradiction:

Improvewater protectionVSAvoidstructure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The inner cover acts as an intermediary element between the lower cover and the electronic components. It provides an additional protective barrier that prevents water from the lower water storage chamber from reaching the accommodation space, thereby enhancing protection without requiring a completely different structural approach.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent introduces a vertical dimension to water management by creating a water storage chamber in the lower portion and using vertically arranged protective barriers (lower cover, inner cover, frame). This dimensional approach allows water to be contained in a separate lower zone, effectively isolating it from the electronic components in the upper zone.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS10326262B2Electrical connection box

Publication Date: 2019.06.18 YAZAKI CORP

AI summary

An electrical connection box includes a frame that has a tubular inner wall and a tubular outer wall surrounding the inner wall, and accommodates an electronic component inside the inner wall a lower cover that covers a lower edge of the outer wall and an inner cover that is disposed inside the lower cover and covers a lower edge of the inner wall.