Electrical Junction Box Connector Alignment via Projection-Recess Fitting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical junction boxes face difficulties in accurately aligning and connecting the main body-side connector with the attachment body-side connector due to improper positioning, often requiring special processing and increasing the size of the box body.
Innovation Solution
A positioning portion is introduced, where the main body-side connector is positioned directly on the case using a projection-recess fitting, allowing for accurate alignment and connection without additional members, and maintaining the external shape of the box body, using elongate connectors with projections and recesses at both ends for stable and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a guide pin and guide groove are provided to improve connector alignment accuracy, then connector alignment accuracy is improved, but device complexity and manufacturing cost increase due to special processing requirements
Solution Approach 1:
The patent removes the guide pin and guide groove from the structure, extracting the unnecessary positioning components that caused complexity. Instead, it relies on the natural positioning capability of the connector housing engagement between the attachment body and box body, achieving alignment without additional special processing features.
Solution Approach 2:
The connector housing serves multiple functions: it provides structural support, enables rotatable mounting, and simultaneously achieves positioning and alignment of the connectors. This multi-functional design eliminates the need for dedicated guide pins or grooves, reducing overall device complexity while maintaining alignment accuracy.
2Stability of the object's composition
If the attachment body is positioned at the supporting portion, then the attachment body is securely supported, but the main body-side connector and attachment body-side connector cannot be aligned accurately
Solution Approach 1:
The patent separates the positioning function in the support direction from the alignment function in the connector connection direction. The supporting portion provides stability in one dimension (support direction), while the connector housing engagement provides alignment in another dimension (connector connection direction), resolving the spatial conflict between support and alignment requirements.
Solution Approach 2:
The connector housing acts as an intermediary element that mediates between the supported attachment body and the box body. It transfers and coordinates the positioning and alignment functions, enabling the attachment body to be securely supported while simultaneously achieving accurate connector alignment through its engagement structure.
Data Source
AI summary
An electrical junction box (10) has a main body-side connector (40) provided in a box body (12). An attachment body-side connector (76) is provided in an attachment body (14) that is separate from the box body (12) and is connected to the main body-side connector (40) by rotating the attachment body (14) on a rotating portion (72) provided at an end of the attachment body (14). The rotating portion (72) is supported by a support (30) on a side of the box body (12) opposite to the main body-side connector (40), and a positioning portion directly positions the main body-side connector (40) with respect to the upper case (20).