Electric Junction Box Sealing Through Hollow Outlet Filling
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Solution Overview
Problem
Existing electric junction boxes face challenges in achieving waterproofing when there is a small gap between the outlet and the electric wire due to the formation of holes or cutouts for binding bands, making it difficult to fill the gap with conventional waterproof silicone resin.
Innovation Solution
A method and design for electric junction boxes that involve pouring a water stop material through a hollow filling portion surrounding the outlet, which includes a first hole for filling, and in some cases, a second hole or covering the distal end of the outlet, ensuring the material is applied over the entire circumference of the wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a binding band is used to fix the electric wire to the outlet, then the electric wire is securely fixed, but the gap between the electric wire and outlet becomes too small to fill with waterproof silicone resin
Solution Approach 1:
The patent divides the waterproofing process into two independent parts: (1) mechanical fixing using a binding band to secure the electric wire to the outlet, and (2) waterproofing using a separate water stop material filling structure. This segmentation allows each function to be optimized independently without interference between fixing strength and gap accessibility.
Solution Approach 2:
The patent introduces a hollow filling portion as an intermediary structure that provides access to the gap between the electric wire and outlet. This filling portion includes a first hole and communicates with the gap, allowing water stop material to be poured in without requiring direct external access to the narrow gap space.
2Ease of operation
If holes or cutouts are formed in the outlet for binding band passage, then the electric wire can be fixed, but waterproofing becomes difficult to achieve
Solution Approach 1:
The patent separates the wire fixation function (achieved through binding bands passing through holes in the outlet) from the waterproofing function (achieved through the hollow filling portion). This allows both holes to remain for easy wire installation while the filling portion provides a separate pathway for waterproofing material.
Solution Approach 2:
The hollow filling portion acts as an intermediary that bridges the outlet and the gap between the electric wire and outlet. It provides an alternative access route for water stop material that does not interfere with the binding band holes, thus maintaining both ease of wire fixation and reliable waterproofing.
3Device complexity
If conventional waterproofing methods are used, then the process is simple, but waterproofing cannot be achieved in small gaps
Solution Approach 1:
The hollow filling portion serves as an intermediary structure that enables water stop material to reach small gaps that are inaccessible to conventional direct application methods. This relatively simple additive structure significantly improves waterproofing effectiveness without introducing complex mechanisms.
Solution Approach 2:
The patent approaches the waterproofing problem from a different dimension by creating a three-dimensional hollow filling portion that surrounds the outlet and electric wire assembly. This volumetric structure provides multiple access pathways (through the first hole and through communication with the gap) rather than relying on single-point access, enabling waterproofing of previously inaccessible areas.
Data Source
AI summary
A water stop material filling method for filling a water stop material into an outlet of an electric wire provided in an electric junction box, the water stop material filling method includes pouring the water stop material through a first hole that is formed in a hollow filling portion surrounding an outside of the outlet and communicating with the outlet.