Integrated Junction Box with Rotatable Cover for Tool-Free Wiring
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Solution Overview
Problem
Conventional lamp assemblies with separate junction boxes and lamp holders result in redundant tooling molds, high production costs, complex assembly processes, low yield rates, and poor interchangeability, requiring a screwdriver for wiring connections, which is inconvenient.
Innovation Solution
An integrated junction box with a terminal receptacle and lamp holder, where a rotatable cover allows for easy electrical connection and disconnection of wires without additional tools, eliminating the need for conducting wires between components and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the junction box and lamp holder are designed as separate components with wiring connections, then the electrical connection function is achieved, but the production cost increases, assembly process becomes complicated, and yield rate decreases
Solution Approach 1:
The patent integrates the junction box and lamp holder into a single integrated junction box assembly. The lamp holder is fixed to the terminal receptacle, eliminating the need for separate components and wiring connections. This merging reduces production costs by eliminating redundant tooling molds and simplifies the assembly process, directly addressing the technical contradiction between ease of manufacture and device complexity.
Solution Approach 2:
The integrated junction box combines multiple functions into a single component: it serves as both the junction box for electrical connections and the lamp holder for mounting the light source. The terminal receptacle with outlet opening provides electrical connection functionality, while the fixed lamp holder provides mounting functionality, eliminating the need for separate components and reducing assembly complexity.
2Ease of manufacture
If the junction box and lamp holder are manufactured by different tooling moulds, then component specialization is achieved, but production cost increases and yield rate decreases
Solution Approach 1:
The patent combines the junction box and lamp holder into a single integrated assembly that can be manufactured as one unit. The terminal receptacle and lamp holder are fixed together to form an integrated structure, eliminating the need for different tooling molds and reducing production costs while improving yield rate by simplifying the manufacturing process.
3Ease of operation
If wiring is fixed on the junction box only with screws, then secure electrical connection is achieved, but the wiring operation becomes impossible without a screw driver, reducing convenience
Solution Approach 1:
The integrated junction box features a self-service wiring mechanism where the outlet opening allows wires to be directly inserted and secured without requiring external tools like screw drivers. The terminal receptacle structure enables direct wire insertion and securing through the outlet opening, making the wiring operation convenient while maintaining secure electrical connection through the integrated design.
4Adaptability or versatility
If each type of junction box is specified for one wiring type, then wiring specificity is achieved, but interchangeability deteriorates
Solution Approach 1:
The integrated junction box design with the terminal receptacle and outlet opening creates a universal structure that can accommodate different wiring types. The outlet opening is configured to pass external connecting wires through and enable electrical connection, providing adaptability for various wiring configurations while maintaining manufacturing precision through the standardized terminal receptacle structure.
Data Source
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AI summary
The invention he present invention provides a lamp assembly and an integrated junction box for disposing a light source. The integrated junction box includes a terminal receptacle and a lamp holder. The terminal receptacle includes an outlet opening for receiving an external connecting wire and electrically connecting the external connecting wire to the terminal receptacle. The cover has a rotatable connection with the terminal receptacle. The cover can rotate to form an open status or a tight status between the outlet opening and the cover, for dis-attaching or fixing the external connecting wire. The cover is disposed over the terminal receptacle, and the outlet opening passes above a side wall of the terminal receptacle. The external connecting wire passes through the outlet opening to electrically connect the terminal receptacle. When the cover rotates to the tight status of the outlet opening, the external connecting wire is fixed at the outlet opening. When the cover rotates to the open status of the outlet opening, the external connecting wire can be dis-attached from the outlet opening.