Junction Box Double Wall Waterproofing Demoldability
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Solution Overview
Problem
Conventional on-vehicle electrical junction boxes face poor demoldability due to the oblong shape of the molding die required for their double-walled structure, leading to deformation issues when releasing the product from the die, while maintaining waterproof performance.
Innovation Solution
The electrical junction box incorporates a double wall structure with a waterproof wall extended towards the outer edge or lower than the component insertion surface, allowing the inner wall to be positioned higher than the component insertion surface, thereby shortening the vertical space between the outer and inner walls and enhancing demoldability without compromising waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inner wall is extended lower than the component insertion surface to prevent water from soaking components, then waterproof performance is improved, but the vertical space between outer wall and inner wall increases, causing oblong molding die shape and poor demoldability
Solution Approach 1:
The patent transitions from a purely vertical extension of the inner wall to a multi-dimensional waterproofing approach. The waterproof wall is configured to extend both toward the outer wall (horizontal dimension) and lower than the component insertion surface (vertical dimension), creating a three-dimensional waterproof barrier that prevents water from reaching components while reducing the vertical gap between walls.
Solution Approach 2:
The waterproof wall is strategically positioned only at the lower end and outer edge of the component receiving section, rather than extending the inner wall throughout its entire length. This localized waterproofing structure prevents water intrusion at critical areas while minimizing the overall vertical space required, thus improving demoldability without compromising waterproof performance.
2Reliability
If the inner wall is extended lower to ensure waterproofing, then components are protected from water, but the molding die becomes oblong and product deformation occurs during release
Solution Approach 1:
The waterproof wall extends in both horizontal and vertical directions, creating a three-dimensional barrier that protects components from water while reducing the vertical gap between walls. This multi-dimensional approach allows the inner wall to be positioned higher than the component insertion surface, resulting in a more compact molding die shape that improves demoldability and reduces product deformation.
Solution Approach 2:
The waterproof wall is strategically positioned only at the lower end and outer edge of the component receiving section, providing localized protection where water intrusion is most likely to occur. This localized approach minimizes the overall vertical space required, allowing the inner wall to be positioned higher and reducing the oblong shape of the molding die, thereby decreasing product deformation during release.
3Ease of manufacture
If the vertical space between outer wall and inner wall is reduced to improve demoldability, then molding die shape becomes more compact, but waterproof performance may be compromised
Solution Approach 1:
The waterproof wall is configured to extend both toward the outer wall (horizontal dimension) and lower than the component insertion surface (vertical dimension), creating a three-dimensional waterproof barrier. This multi-dimensional approach allows the vertical gap between walls to be reduced for improved demoldability while maintaining effective waterproof protection through the horizontal extension of the waterproof wall.
Solution Approach 2:
The waterproof wall is strategically positioned at the lower end and outer edge of the component receiving section, providing localized waterproof protection where it is most needed. This localized approach enables the inner wall to be positioned higher, reducing the vertical gap and improving demoldability, while still maintaining waterproof performance through the strategically placed waterproof wall.
Data Source
AI summary
An electrical junction box includes: a frame; and a block having a double wall defined by outer and inner walls. At a position where the double wall and a component receiving section of the block are opposite to each other, a lower end of the inner wall is positioned higher than a component insertion surface at a lower end of the component receiving section, and a waterproof wall is provided on the lower end and an outer edge at the double wall side of the component receiving section. The waterproof wall is defined by a first waterproof portion extended horizontally toward the outer wall from the lower end and the outer edge at the double wall side of the component receiving section, and a second waterproof wall extended downward and parallel to the outer wall from an end at the outer wall side of the first waterproof wall.