Integral Wiring Box Casting Eliminates Assembly Gaps

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Solution Overview

Problem

Wiring boxes are not adequately resistant to environmental forces and often fail to meet standards due to poor sealing and assembly issues, leading to water and dirt ingress, and they require multiple assembly processes which increase complexity and failure rates.

Innovation Solution

The development of an integral wiring box formed as a single, unitary component through casting, with plates and walls formed contemporaneously, eliminating the need for separate attachment and reducing material and labor costs, while enhancing weatherproofing and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wiring boxes are assembled from multiple separate components (housing and plates), then the box can be manufactured and assembled, but the assembly requires many secondary processes and has poor resistance to environmental forces

Engineering Contradiction:

Improveresistance to environmental forcesVSAvoidnumber of assembly processes

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the housing and plates into a single integral component formed by casting. This eliminates the need for separate assembly processes to attach plates to the housing, reducing the number of secondary processes while improving resistance to environmental forces by creating a unified structure without weak joints.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If separate plates are attached to the housing, then the box can be assembled, but the plate attachment fails under environmental conditions tested by UL514A

Engineering Contradiction:

Improveplate attachment integrityVSAvoidmanufacturing process simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The housing and plates are merged into a single cast component, eliminating the plate attachment issue entirely. The integral structure ensures plate attachment integrity by making the plates part of the housing itself, while the casting process maintains ease of manufacture through a single-step production method.

Inventive Principle:

Principle #5Merging (Combining)

3Object-affected harmful factors

If multiple components are used to form the box, then the box can be constructed, but water and dirt can enter through assembly gaps

Engineering Contradiction:

Improvewater and dirt ingressVSAvoidnumber of components

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

By combining all components into a single integral casting, the patent eliminates assembly gaps where water and dirt could penetrate. The unified structure provides inherent sealing without requiring additional gaskets or seals, reducing both component count and vulnerability to environmental contamination.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If steel strips are crimped to the box to meet UL514A, then the box can pass the test, but a large percentage of boxes still fail the standard

Engineering Contradiction:

ImproveUL514A test pass rateVSAvoidattachment method complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The integral casting design eliminates the need for separate attachment methods like crimped steel strips. By making the plates part of the housing structure, the design inherently passes UL514A testing without relying on additional attachment components or complex assembly processes, achieving both high reliability and simplicity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9263868B2Integral box

Publication Date: 2016.02.16 SIGMA ENGINEERED SOLUTION CORP

AI summary

In one embodiment, an integral box comprises a base with walls, with plate(s) extending from a side wall(s). Opening(s) in the side wall(s) and/or the base allow wiring to pass into the box. This box is formed as a single, unitary component.