Junction Box Housing With Nested Engagement Grooves

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Solution Overview

Problem

Existing electrical junction box housing structures are prone to deformation or damage of engagement parts, leading to assembly issues and space inefficiency, particularly due to the need for external projections and guide rails which can be damaged and cause rattling during low-temperature operations.

Innovation Solution

The structure features a groove-like depression on the external side surface of the electrical junction box with an engagement convex part of equal or lesser height than the depression, eliminating external protrusions and allowing the engagement convex part to be formed within the depression, which engages with internal parts to prevent slipping and eliminates the need for guide rails, enhancing assemblability and space efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If elastic engagement arms with engagement projections are provided on outer surfaces of the electrical junction box, then the electrical junction box can be engaged with the housing box, but the engagement parts are prone to deformation or damage during low-temperature operations

Engineering Contradiction:

Improveengagement reliabilityVSAvoidengagement part durability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

Instead of providing engagement projections on the electrical junction box that protrude outward (conventional approach), the invention inverts the design by providing engagement convex parts within groove-like depressions on the outer surfaces. This inversion protects the engagement parts from external damage while maintaining engagement functionality.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The engagement convex parts are nested within groove-like depressions on the outer surfaces of the electrical junction box. This nesting structure protects the engagement parts from deformation and damage during low-temperature operations while still allowing them to engage with the housing box.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If guide rails are provided to protect engagement arms, then the engagement parts are protected, but extra space is required reducing space efficiency

Engineering Contradiction:

Improveengagement part protectionVSAvoidhousing space efficiency

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The protective function previously requiring separate guide rails is merged into the groove-like depressions themselves. The grooves serve both as guides for engagement and as protective structures, eliminating the need for additional guide rails and improving space efficiency.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If engagement projections are provided on outer surfaces, then engagement with housing box is achieved, but the structure is vulnerable to damage during dropping or hitting

Engineering Contradiction:

Improveengagement functionalityVSAvoidimpact damage vulnerability

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The groove-like depressions provide beforehand cushioning and protection for the engagement convex parts. When the electrical junction box is dropped or hit, the grooves absorb and distribute the impact forces, preventing damage to the engagement parts before they can be compromised.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 configuration reduces the risk of deformation or damage, ensures smooth assembly without rattling, and eliminates the need for guide rails, improving assemblability and contributing to cost reduction by minimizing die processing and enhancing space-saving design.

Implementation Method 1

an internal engagement part pressed and deformed by the engagement convex part in insertion of the electrical junction box to allow passing of the engagement convex part over the internal engagement part

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS7459631B2Structure for housing electrical junction box in housing box

Publication Date: 2008.12.02 YAZAKI CORP

AI summary

Provided is a structure for housing an electrical junction box in a housing box by inserting the electrical junction box into the housing box from above and also for fixing the electrical junction box to the housing box so as to prevent slipping-off thereof by engagement between engagement parts provided on external side surfaces of the electrical junction box and engagement parts provided on internal side surfaces of the housing box, both of which face each other in parallel with an insertion direction in insertion of the electrical junction box. Moreover, groove-like depressions extended along the insertion direction into the housing box are provided in the external side surfaces of the electrical junction box, and engagement convex parts are provided in the depressions. Furthermore, engagement projections engaged with the engagement convex parts are provided on the internal side surfaces of the housing box. As depressions behind the engagement convex parts in the insertion direction, die-releasing holes for injection molding for forming locking parts of the electrical junction box are used.