Vehicle Junction Box Waterproofing via Segmented Cover and Adhesion
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Solution Overview
Problem
Conventional electrical junction boxes in vehicles are prone to water accumulation between the housing box and connectors, leading to corrosion and potential damage to the electrical device, especially when exposed to saltwater.
Innovation Solution
The electrical junction box design includes a connector with a tubular portion and a protruding portion, a housing box with a cover portion, and an adhering member between the protruding portion and the cover, which prevents water from entering the space between the connector and the housing box by using a second cover portion positioned above the connector and adhering members to create a sealed environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an adhering member is provided between the housing box and connector to hermetically seal the insertion port, then water is prevented from entering the housing box, but saltwater accumulates in the space between the housing box and connector causing corrosion
Solution Approach 1:
The cover structure is divided into multiple segments: a first cover portion that covers the side surface of the connector, and a second cover portion that covers the upper surface. This segmentation allows each cover portion to perform its specific sealing function while preventing water accumulation in different areas, thereby resolving the contradiction between waterproofing and corrosion prevention
Solution Approach 2:
The sealing approach is extended from a single horizontal plane to multiple dimensions by adding the second cover portion that covers the upper surface. This multi-dimensional sealing prevents water from accumulating above the connector, addressing the corrosion issue while maintaining the waterproofing function
2Reliability
If the insertion port is hermetically sealed by the connector and adhering member, then water entry is prevented, but the space between housing box and connector becomes a water trap
Solution Approach 1:
The harmful element (water) is extracted from the enclosed space by providing drainage holes in the first cover portion. These holes allow water that enters the space between the housing box and connector to be drained outward, preventing water accumulation while maintaining the hermetic seal at the insertion port
Solution Approach 2:
The adhering member functions as a flexible sealing film that conformally seals the insertion port while the cover portions create a protective shell structure. This combination maintains sealing performance while the drainage holes in the shell prevent water trapping
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
This configuration effectively prevents water accumulation and reduces the risk of corrosion, ensuring the electrical device remains protected from moisture and saltwater exposure.
Implementation Method 1
an adhering member that is provided between the protruding portion of the connector and the first cover portion of the housing box and adheres to the protruding portion and the first cover portion
Data Source
AI summary
In a connector of an electrical junction box, a protruding portion protrudes away from a tubular portion from a bottom wall of the tubular portion whose one end face is open. In a housing box, a tubular first cover portion protrudes outward from a circumferential edge portion of an insertion port, and a second cover portion protrudes from a portion of a front end face of the first cover portion. A portion of the protruding portion of the connector is inserted into the insertion port. The first cover portion covers the protruding portion, and the second cover portion covers the protruding portion with a space interposed between the second cover portion and the protruding portion 22. An adhering member is between the protruding portion of the connector and the first cover portion of the housing box and adheres to the protruding portion and the first cover portion.