Junction Box Cable Fixing via Outer Extension Flange
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing junction boxes fail to effectively and reversibly secure cables against mechanical stresses, particularly lateral displacement due to bending forces, while also preventing insulating material leaks, especially in aggressive environments, and require complex installation processes.
Innovation Solution
The junction box design includes a first half-shell with outer extensions for fixing cables using flanges or flexible collars before closure, and a detachable wedge for accommodating cables of different diameters, allowing for easy installation and ensuring the box can be filled with insulating material without leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cables are fixed inside the junction box using internal retention means, then cable fixation is achieved, but installation becomes complicated and cables cannot be fixed before box closure
Solution Approach 1:
The cable fixation function is extracted from the internal space of the junction box and relocated to the external surface through the first outer extension. The flange is mounted on the outer extension, allowing cables to be fixed outside the box before closure, thereby simplifying installation while maintaining effective cable retention.
2Ease of operation
If flanges are embedded in insulating material for cable fixation, then cable fixation before filling is achieved, but flanges become difficult to detach after filling
Solution Approach 1:
The flange is extracted from the insulating material and relocated to the outer extension of the box. This positioning ensures the flange remains accessible and detachable even after the box is filled with insulating material, while still providing effective cable fixation before filling.
3Reliability
If individual retention means are provided for each cable, then lateral displacement of each cable is prevented, but labor time and installation cost increase considerably
Solution Approach 1:
Multiple cable retention functions are merged into a single flange structure mounted on the outer extension. The flange simultaneously secures multiple cables against lateral displacement, eliminating the need for individual retention means for each cable and significantly reducing installation time and labor costs.
4Productivity
If junction boxes are buried before resin cures to save time, then installation time is reduced, but mechanical stresses compromise box tightness and cable retention
Solution Approach 1:
Cables are preliminarily fixed to the outer extension using the flange before the box is closed and filled with resin. This preliminary fixation ensures cables are securely retained against mechanical stresses during burial, even before the resin has cured, allowing immediate burial without compromising tightness or cable retention.
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The box (1) has adjacent passage orifices for passage of a main cable (2) and a lead cable (4) and for filling the box with an insulating material e.g. curable resin or gel. Half-shells (9, 10) are divided by a joint (11) traversing the passage orifices. The half-shell (9) includes an exterior extension (12) at the level of the passage orifices, where one of the orifices is made of biodegradable plastic material. The extension has a set of orifices for fixing a strap (18) against a pressure screw (22) to simultaneously lock the cables against concave housings in the extension. An independent claim is also included for a method for a method for installing a junction of two cables.