Electrical Junction Box Bonder Cap Retention

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Solution Overview

Problem

Conventional electrical junction boxes face difficulties in inserting terminal-attached wires due to the design of the frame, which also complicates the manufacturing process and increases costs, and struggle to prevent the bonder cap from falling out without using a bundling tie.

Innovation Solution

The design includes a frame with a bonder cap accommodating part and a terminal-attached wire accommodating part, where the edge of the bonder cap accommodating part features a low profile and a projecting portion, and a cover is attached to prevent the bonder cap from falling out by utilizing the elastic resilience of the wire bundle.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the edge forming the insertion port of the bonder cap accommodating part projects beyond the edge forming the insertion port of the terminal-attached wire accommodating part, then the bonder cap is prevented from falling out, but the terminal-attached wire becomes hard to insert into the terminal-attached wire accommodating part

Engineering Contradiction:

Improvebonder cap retentionVSAvoidwire insertion ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The edge of the bonder cap accommodating part is segmented into two functional portions: a first portion that projects beyond the terminal-attached wire accommodating part edge to prevent bonder cap dropout, and a second portion that is lowered to allow easy wire insertion. This segmentation resolves the contradiction by dividing the edge into specialized zones with different functions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the bonder cap accommodating part edge are given different local qualities: the first portion has a higher projection to provide retention function, while the second portion has a lower profile to provide insertion function. This local differentiation allows each zone to optimize its specific function without compromising the other.

Inventive Principle:

Principle #3Local quality

2Reliability

If a threading hole and bundling tie are used to prevent the bonder cap from falling out, then the bonder cap is secured, but the mold shape becomes complicated and manufacturing cost increases

Engineering Contradiction:

Improvebonder cap retentionVSAvoidmold complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The external bundling tie and threading hole components are extracted and eliminated. Instead, the retention function is integrated directly into the bonder cap accommodating part edge through the projected first portion, simplifying the mold shape and reducing manufacturing complexity while maintaining reliable bonder cap retention.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The retention function, previously performed by a separate bundling tie system, is merged into the bonder cap accommodating part itself through the projected edge portion. This integration eliminates the need for additional components and simplifies the manufacturing process.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If the wall of the bonder cap accommodating part is lowered to allow easy wire insertion, then wire insertion becomes easy, but the bonder cap becomes easily detachable

Engineering Contradiction:

Improvewire insertion easeVSAvoidbonder cap retention

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The accommodating part edge is segmented into a first portion for retention (projected) and a second portion for insertion (lowered). This segmentation allows the insertion zone to be lowered for easy wire access while the retention zone remains projected to prevent bonder cap dropout.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Local quality is applied by giving different heights to different portions of the edge: the first portion maintains a higher projection locally to ensure retention, while the second portion is lowered locally to facilitate wire insertion. This localized differentiation resolves the contradiction between retention and insertion ease.

Inventive Principle:

Principle #3Local quality

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 allows easy insertion of terminal-attached wires and prevents the bonder cap from falling out without a bundling tie, simplifying the manufacturing process and reducing costs.

Implementation Method 1

utilizing the elastic resilience of the wire bundle

Methodology Applied

Scientific EffectElastic resilience: Elasticity

Data Source

PatentUS9203224B2Electrical junction box

Publication Date: 2015.12.01 YAZAKI CORP

AI summary

Provided is an electrical junction box which prevents a bonder cap from falling out of a bonder cap accommodating part without using a bundling tie. The electrical junction box includes a frame having a bonder cap accommodating part and a terminal-attached wire accommodating part, and a cover. An edge forming an insertion port of the bonder cap accommodating part includes a low pro file portion with the same height as that of an edge of the terminal-attached wire accommodating part and a projecting portion projecting beyond the low profile portion. In a state where the cover is attached to the frame, a distance between the low profile portion and the cover is longer than the full length of the bonder cap, and a distance between the most projected portion of the projecting portion and the cover is shorter than the full length of the bonder cap. The wire bundle outside the bonder cap accommodating part is bent toward the low profile portion.