Elastically Deformable Hinge Junction Box Waterproofing
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Solution Overview
Problem
The existing electrical junction boxes for motor vehicles face issues with long-term waterproofing and size increase due to the peeling off of tape used for water prevention, and the bundle of electric wires is easily displaced during assembly, leading to tape peeling and reduced assembly efficiency.
Innovation Solution
An electrical junction box design featuring an insertion portion with an elastically-deformable hinge allowing the second divided piece to adjust to wire thickness, using binding band insertion portions that decrease in width for secure fastening without tape, facilitating easy assembly and preventing water ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tape is wound around the insertion portion and bundle of electric wires to prevent water entry, then waterproof function is achieved, but the tape can be peeled off during long-term use and the junction box size increases
Solution Approach 1:
The invention extracts and eliminates the tape component from the waterproofing system. Instead of using tape that can be peeled off, the design creates an integrated waterproof structure where the cover itself forms a seamless waterproof barrier with the frame through precise fitting and sealing structures, removing the need for separate tape elements that degrade over time
Solution Approach 2:
The waterproofing function is merged into the structural design of the cover and frame themselves. The cover and frame are designed with integrated sealing features where the cover fits onto the frame to create a unified waterproof enclosure, eliminating the need for separate tape components and creating a more reliable long-term waterproof solution
2Stability of the object's composition
If the bundle of electric wires is fixed to the insertion portion first divided piece by a banding band before attaching the lower cover, then the wires are secured, but the angled shape causes easy displacement and reduces assembly efficiency
Solution Approach 1:
The binding band insertion portions are pre-formed on the insertion portion first divided piece and second divided piece during manufacturing. This preliminary preparation allows the binding band to be quickly installed without requiring complex positioning or adjustment during assembly, significantly improving assembly efficiency while maintaining secure wire fixation
Solution Approach 2:
The binding band acts as an intermediary element that connects the insertion portion first divided piece and second divided piece. The binding band insertion portions provide guided pathways for the binding band, ensuring proper positioning and secure fastening of the wire bundle without requiring precise manual alignment, thus improving both fixation stability and assembly efficiency
3Adaptability or versatility
If the insertion portion second divided piece is made elastically deformable via hinge portion, then adaptability to different wire thicknesses is improved, but the structure complexity increases
Solution Approach 1:
The insertion portion second divided piece is designed with elastic deformability through the hinge portion, allowing it to change its physical state from rigid to flexible. This parameter change enables the piece to adapt to different wire bundle thicknesses by elastically deforming to accommodate varying sizes, providing versatility without requiring multiple different components
Solution Approach 2:
The hinge portion introduces dynamic capability to the insertion portion second divided piece, allowing it to move and adjust its position relative to the first divided piece. This dynamic adjustment mechanism enables automatic adaptation to different wire thicknesses through elastic deformation, providing versatility while maintaining a relatively simple single-piece structure
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 design ensures long-term waterproofing without tape, reduces the junction box size, and simplifies assembly by securely fastening the wires with binding bands, enhancing production efficiency and reducing production costs.
Implementation Method 1
an insertion portion second divided piece integrally formed with the cover via an elastically-deformable hinge portion and protruding outside the cover
Data Source
AI summary
There is provided an electrical junction box which can prevent water from entering from an insertion portion for the long term and which can be assembled easily. The electrical junction box includes a frame, a lower cover and an insertion portion through which a bundle of electric wires is passed. The insertion portion includes an insertion portion first divided piece having a semicircular cross-section and integrally formed with the frame and an insertion portion second divided piece having a semicircular cross-section and integrally formed with the lower cover via a hinge portion. In an unloaded condition, the insertion portion second divided piece is positioned at a location farthest from the insertion portion first divided piece. The divided pieces are provided with binding band insertion portions through which a binding band is passed.