Electrical Junction Box Rib Layout for Thermal Warping Suppression
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Solution Overview
Problem
The increase in the number and size of electronic components in electrical junction boxes due to functional diversification in vehicles leads to warping issues caused by thermal expansion differences, which are not adequately addressed in existing designs.
Innovation Solution
The electrical junction box incorporates inner and outer ribs with specific thickness and orientation configurations to offset thermal contraction differences, particularly in the second wall, thereby suppressing warping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of electronic components is increased to accommodate more functions, then the functionality is improved, but thermal expansion differences cause warping in the junction box
Solution Approach 1:
The patent applies local quality by providing ribs at specific locations (end portions of the second wall) rather than uniformly throughout the structure. These localized ribs create regions of different rigidity to counteract thermal expansion differences at critical areas where warping occurs, allowing the overall structure to maintain stability while accommodating increased functionality.
Solution Approach 2:
The patent employs asymmetry by positioning ribs asymmetrically at end portions of the second wall rather than distributing them uniformly. This asymmetric arrangement creates differential rigidity that specifically addresses thermal expansion issues at the ends of the housing, where warping is most likely to occur due to heat generation from electronic components.
2Quantity of substance
If the size of the junction box is increased to accommodate more components, then the component capacity is improved, but the structural stability deteriorates due to heat-induced warping
Solution Approach 1:
Rather than increasing the overall size uniformly, the patent introduces localized ribs at end portions of the second wall. These ribs provide targeted reinforcement at critical areas susceptible to warping, allowing the junction box to maintain larger size for component capacity while preserving structural stability through localized rigidity enhancement.
Solution Approach 2:
The patent segments the second wall by introducing ribs that divide the continuous wall structure into distinct regions. This segmentation creates zones of different rigidity, with the ribbed end portions providing enhanced stability against thermal warping while the rest of the structure maintains the necessary size for component accommodation.
3Stability of the object's composition
If ribs are added to the second wall to suppress warping, then the structural stability is improved, but the device complexity increases
Solution Approach 1:
The patent minimizes device complexity by applying ribs only at specific end portions of the second wall rather than throughout the entire structure. This localized approach provides adequate warping suppression with minimal additional structural elements, avoiding unnecessary complexity while maintaining structural stability at critical areas.
Solution Approach 2:
The patent applies partial action by providing ribs only where most needed (at end portions of the second wall) rather than uniformly across the entire structure. This partial reinforcement is sufficient to suppress warping caused by thermal expansion differences, achieving the desired stability effect with minimal structural complexity.
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
The solution effectively reduces warping by balancing thermal contraction disparities, maintaining structural integrity and reducing the overall size of the junction box.
Implementation Method 1
a difference in contraction that has occurred between the second wall and the inner rib caused by a difference in amount of heat generated during operation remains is offset by a difference in contraction that has occurred between the second wall and the outer rib
Data Source
AI summary
Provided is an electrical junction box that includes a bottom wall that comes into contact with a mount target such as a battery pack, and a ceiling wall opposing the bottom wall, an inner rib protrudes from an inner surface of the ceiling wall, and a second outer rib protrudes from an outer side surface that is opposite to the inner surface of the ceiling wall.