Automotive Junction Box Cover Support for Stress Reduction
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Solution Overview
Problem
The existing electric junction boxes for automobiles require additional space for connector housings, leading to increased size due to projections on the outer surface, which causes stress at junction portions of conductive patterns and makes the components larger than necessary.
Innovation Solution
An electric junction box design featuring a printed wiring board with a tubular connector housing and a cover having a notch and support that overlaps with the edge of the connector housing, eliminating the need for external projections and reducing size, while also preventing stress at junctions and potential damage from mating connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a projection is added to the connector housing to prevent stress at junction portions, then reliability is improved, but the device size increases
Solution Approach 1:
The support structure is moved from a horizontal projection on the connector housing to a vertical support extending from the cover downward. This dimensional change allows the support function to be achieved without increasing the horizontal footprint of the connector housing, thus preventing stress at junction portions while maintaining compact overall dimensions.
Solution Approach 2:
A separate support structure is introduced as an intermediary element between the cover and the connector housing. This support acts as a mediator that provides the necessary structural reinforcement to prevent stress at junction portions without requiring modifications that would increase the connector housing size.
2Strength
If heat-resistant material is used for the connector housing to prevent damage from mating connectors, then strength is improved, but manufacturing cost increases
Solution Approach 1:
The connector housing is divided into two functional zones: the main body made of standard material for cost-effective manufacturing, and the edge portion reinforced with rib structures for strength. This segmentation allows the housing to provide adequate protection against mating connector damage without requiring expensive heat-resistant material throughout the entire housing.
Solution Approach 2:
The connector housing combines standard plastic material with reinforced rib structures at critical edges. This composite approach provides the necessary strength to resist damage from mating connectors while avoiding the high cost of using heat-resistant material for the entire housing, achieving a cost-effective balance between strength and manufacturing cost.
Data Source
AI summary
An electric junction box to prevent stress from working at a junction of conductive pattern of a connector terminal mounted on a printed wiring board and curtail its size, comprises, a printed wiring board, a connector including a terminal connected with a conductive pattern on the printed wiring board, and a connector housing accommodating the terminal, and a cover adapted to receive the printed wiring board therein and including a hole disposed on an outer wall of the cover and passing the connector therethrough. The lower cover is provided with a support adapted to overlap with a part of an edge of the connector housing surrounding the terminal, and position the part between the printed wiring board and the support.