Vehicle Junction Box Drain Groove Water Ingress
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Solution Overview
Problem
Traditional junction boxes on vehicles fail to adequately prevent water from leaking into the electric distribution portion, particularly where high electric current flows, due to gaps between the box body and the upper cover, which can lead to water ingress from the engine room.
Innovation Solution
A junction box design featuring a side cover with a drain groove on its upper face, extending inward beyond the down wall portion of the upper cover, and a downward slope towards a drain hole, combined with a water stop projecting portion along the lower edge of the upper cover, to guide and drain water away from the electric distribution portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If only an upper cover is used to cover the upper end edges of the side cover case, then the structure is simple, but water cannot be sufficiently prevented from leaking inside the box body
Solution Approach 1:
The water prevention function is segmented into multiple components: the upper cover provides initial coverage, the drain groove collects water that penetrates through, and the downward slope directs water toward the drain hole. This segmentation allows each component to focus on a specific aspect of water prevention while maintaining overall structural simplicity.
Solution Approach 2:
The drain groove acts as an intermediary element between the potential water entry point (above the side cover) and the drainage exit (drain hole). It mediates the water flow by collecting and redirecting it away from the electric distribution portion, preventing water accumulation in critical areas.
2Volume of moving object
If the electric distribution portion is located at the part where the side cover is attached, then space utilization is efficient, but water leakage risk increases to the electric distribution portion
Solution Approach 1:
The drain groove serves as a protective intermediary between the side cover attachment area (where electric distribution portion is located) and any potential water sources. It intercepts water before it can reach the electric distribution portion, allowing efficient space utilization without compromising electrical component safety.
Solution Approach 2:
The design converts the potential harm of water leakage into a beneficial drainage system. The drain groove and downward slope transform water that would otherwise damage electrical components into a controlled flow that is safely directed outside the box body through the drain hole.
3Reliability
If a drain groove and downward slope are added to guide water away, then water prevention capability is improved, but device complexity increases
Solution Approach 1:
The drain groove and downward slope are merged into a single integrated feature on the upper face of the side cover case. This combination achieves effective water guidance and drainage functionality without requiring separate components, thereby improving water prevention capability while minimizing the increase in device complexity.
Solution Approach 2:
The upper face of the side cover case serves multiple functions: it provides structural support for the side cover attachment and simultaneously incorporates the drain groove with downward slope for water drainage. This multi-functionality reduces the need for additional dedicated water management components, balancing reliability improvement with structural simplicity.
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
Effectively prevents water from leaking into the electric distribution portion by collecting and directing it through the drain groove and hole, ensuring it is drained outside the box body, thus protecting sensitive electrical components from moisture.
Implementation Method 1
a downward slope is formed towards the drain hole on a bottom face of the drain groove
Data Source
AI summary
A junction box includes a box body, an upper cover, and a side cover. The box body has a side wall portion, an electric distribution portion, and a drain hole which is located at the inside of the side wall portion. The upper cover has a top panel and a down wall portion which are downwardly provided from the peripheral end of the top panel. The side cover has a terminal connected to the electric distribution portion and a case portion which covers the terminal. A drain groove is provided on an upper face of the case portion along the side wall portion. A downward slope is formed towards the drain hole on a bottom face of the drain groove.