Vehicle Junction Box Resonance Damping via Composite Cover
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Solution Overview
Problem
Conventional metal casing electrical junction boxes installed in vehicles are prone to vibration, leading to noise generation due to the casing components colliding with each other.
Innovation Solution
An electrical junction box design featuring a synthetic resin case main body with a metal cover, where the case main body has an abutment portion that contacts the side wall of the cover, but not the end portion, to absorb vibrations and reduce noise, along with a heat dissipation member that functions as an accommodating container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal casing is used for the electrical junction box, then the strength and durability are improved, but the vibration and noise generation increase due to the thin thickness of the metal casing
Solution Approach 1:
The patent applies composite materials by combining a metal cover with a synthetic resin case main body. The metal cover provides strength and durability, while the synthetic resin case main body absorbs vibration and reduces noise generation. This composite structure resolves the contradiction between needing strong material (metal) and avoiding noise (synthetic resin).
Solution Approach 2:
The patent applies local quality by providing an abutment portion on the case main body that specifically contacts the side wall of the metal cover. This localized contact structure suppresses vibration at the critical interface between metal and resin components, preventing noise generation while maintaining the overall strength benefits of the metal cover.
2Object-generated harmful factors
If the metal casing thickness is increased to reduce vibration, then the noise generation is suppressed, but the weight and space occupation increase
Solution Approach 1:
The patent uses composite materials where the synthetic resin case main body serves as a vibration-absorbing component that replaces the need for thicker metal walls. The resin material inherently dampens vibration, allowing the metal cover to remain thin while still achieving effective vibration suppression without increasing overall weight.
Solution Approach 2:
The abutment portion acts as an intermediary structure that facilitates vibration absorption. By providing a dedicated contact surface on the case main body that abuts against the metal cover's side wall, it creates an effective vibration damping interface without requiring increased material thickness, thus avoiding additional weight.
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
Effectively suppresses noise generation during vehicle installation by absorbing vibrations and enhances heat dissipation while minimizing component count.
Implementation Method 1
the case main body is provided with an abutment portion that abuts on a portion of the side wall of the cover, but not on an end portion of the side wall that is located on the side facing away from the covering wall... vibration is suppressed due to the cover abutting on the abutment portion of the case main body
Implementation Method 2
An electrical junction box design featuring a synthetic resin case main body with a metal cover, where the case main body has an abutment portion that contacts the side wall of the cover, but not the end portion, to absorb vibrations and reduce noise, along with a heat dissipation member that functions as an accommodating container
Data Source
AI summary
An electrical junction box includes a circuit structure, a case main body made of a synthetic resin and having an accommodating portion that accommodates the circuit structure, and a cover 30 made of a metal and that is attached to the case main body, covering the accommodating portion thereof. The cover has a covering wall that covers the accommodating portion of the case main body and a side wall that is continuous with the covering wall and that is disposed around the case main body. The case main body is provided with an abutment portion that abuts on a portion of the side wall of the cover, but not on an end portion of the side wall that is located on the side facing away from the covering wall.