Embedded-Molded Junction Box Assembly for Simpler Waterproof Manufacturing
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Solution Overview
Problem
The manufacturing process of junction boxes is complex and inefficient, requiring multiple assembly steps and resulting in high costs due to the need for separate production and assembly of various components, including a box body, connector housing, connector core, and light guide post, along with the necessity for waterproof sealing.
Innovation Solution
The integration of the connector core and connector housing directly into the box body during an embedded injection molding process, eliminating the need for separate assembly and sealing steps, and allowing for simultaneous formation of terminal and light guide post holes, thereby simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If separate production and assembly of box body, connector housing, connector core, and light guide post are used, then component flexibility and ease of repair are improved, but manufacturing complexity and time increase significantly
Solution Approach 1:
The patent merges the box body, connector housing, and connector core into a single integrated structure formed by injection molding. The connector housing and connector core are embedded directly into the box body during the molding process, eliminating the need for separate assembly steps while maintaining functional separation of components.
Solution Approach 2:
The connector housing and connector core are prepared as pre-formed inserts before the injection molding process. These pre-prepared components are then embedded into the box body during molding, allowing the integration to occur in advance rather than requiring post-assembly operations.
2Manufacturing precision
If multiple assembly steps are used to install connector core, connector housing, and light guide post, then component quality control is improved, but manufacturing efficiency decreases
Solution Approach 1:
The patent combines multiple assembly operations (installing connector core, connector housing, and light guide post) into a single injection molding operation. All components are positioned and integrated simultaneously during the molding process, eliminating sequential assembly steps while maintaining precise positioning through the molding technique.
Solution Approach 2:
The injection molding process automatically positions and integrates the connector housing and connector core into the box body without requiring manual assembly operations. The molding process itself performs the assembly function, reducing labor and time requirements.
3Reliability
If injection grooves for sealant are formed and separate sealing steps are performed, then waterproof reliability is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent integrates the sealing function into the injection molding process itself. The mold cavity and insert arrangement create inherent sealing interfaces during molding, eliminating the need for separate sealing operations while maintaining waterproof integrity through the molded joint design.
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 approach significantly reduces manufacturing complexity, improves efficiency, and lowers costs by integrating key components during molding, eliminating the need for separate assembly and sealing, resulting in a streamlined production process for junction boxes.
Implementation Method 1
The integration of the connector core and connector housing directly into the box body during an embedded injection molding process
Data Source
AI summary
A junction box includes a box body, a connector core, and a connector housing. The connector core is integrally molded with the box body. The connector housing is formed separately from the box body and the connector core and is embedded within the box body during molding of the box body and the connector core.