Battery Junction Box Mounting Structure to Prevent Surface Flexure
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Solution Overview
Problem
Existing electrical junction boxes face issues with flexure of the surface abutting the mount target during attachment, leading to improper mounting due to the collar and mount target failing to engage properly.
Innovation Solution
Incorporation of a flexure preventing mechanism near the mount portion, featuring an engaging portion on the first case and an engaged portion on the second case, which engage upon assembly, along with a check window to verify proper engagement, ensuring the junction box is securely attached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical junction box is mounted from the bottom side with a collar and bolt, then the threaded connection can be secured, but the bottom surface may flex downward due to the weight of the housing, preventing proper abutment between the collar and mount target
Solution Approach 1:
The patent introduces a support rib that extends from the inner surface of the bottom surface toward the outer surface, positioned to support the collar before the mounting operation occurs. This preliminary structural support prevents the bottom surface from flexing downward during the threading operation, ensuring that the collar can properly abut against the mount target without interference from surface deformation.
Solution Approach 2:
The patent divides the bottom surface into multiple regions by introducing support ribs that segment the continuous surface into supported and unsupported zones. The support rib creates a localized structural reinforcement zone that specifically addresses the flexure problem in the mounting area while maintaining the overall integrity of the bottom surface.
2Reliability
If the bottom surface is reinforced to prevent flexure, then proper mounting can be achieved, but the device complexity increases
Solution Approach 1:
The patent applies local quality by introducing a support rib that provides reinforcement only in the specific area where it is needed - the region surrounding the mounting hole and collar. Rather than reinforcing the entire bottom surface uniformly, the support rib is strategically positioned to provide localized structural support, thereby preventing flexure at the critical mounting point while minimizing the overall structural complexity and material usage.
Data Source
AI summary
Provided is an electrical junction box that includes a fastening portion to be used for mounting the electrical junction box to a battery pack, and is to be mounted, from outer surface thereof, to the battery pack, the fastening portion is positioned in a central portion of an outer surface, and a flexure preventing mechanism for preventing flexure of the outer surface is provided in the vicinity of the fastening portion.