Junction Box Single Bolt Coupling Mechanism
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Solution Overview
Problem
Conventional junction boxes have complex structures that increase manufacturing costs, occupy large spaces, and reduce coupling accuracy due to the need for multiple bolting units and complex mechanisms for coupling and decoupling connectors and sockets, making them unsuitable for narrow installations and efficient use.
Innovation Solution
A simplified junction box design using a single coupling bolt and nut system that allows for up/down movement of the main body relative to the lower cover, reducing the number of components and eliminating the need for complex mechanisms, while incorporating guide units for accurate movement and provisional assembling features to facilitate easy coupling and decoupling of connectors and sockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple bolting units are installed in each connector and socket for coupling and decoupling, then the coupling and decoupling function is achieved, but the device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent merges multiple bolting units into a single integrated bolting unit that spans across multiple connectors and sockets. This single bolting unit replaces the conventional approach of having separate bolting units for each connector-socket pair, thereby reducing the total number of components while maintaining the coupling and decoupling functionality across all connections simultaneously.
Solution Approach 2:
The single bolting unit is designed to serve multiple functions by coupling and decoupling multiple connectors and sockets at once. Instead of being dedicated to a single connection point, this universal bolting unit can engage with multiple connection points along its length, allowing one component to perform the work of several individual bolting units.
2Ease of operation
If multiple bolting units are installed in each connector and socket, then the coupling function is achieved, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple separate bolting units into a single integrated component, which reduces the total number of parts that need to be manufactured, stored, and assembled. This merging approach directly reduces manufacturing costs by eliminating redundant components while preserving the essential coupling function across multiple connectors and sockets.
3Ease of operation
If bolting units are installed in each connector and socket, then the coupling function is achieved, but the installation space increases
Solution Approach 1:
The patent consolidates multiple bolting units into a single extended bolting unit that occupies a linear space along the array of connectors and sockets. This merging reduces the overall installation footprint by eliminating the need for multiple separate mounting locations, thereby saving space in the junction box while maintaining full coupling functionality.
4Device complexity
If a single coupling bolt and nut system is used to reduce components, then manufacturing cost decreases and space is reduced, but the coupling accuracy may be affected
Solution Approach 1:
The patent incorporates preliminary positioning features such as guide holes and guide pins that ensure accurate alignment of connectors and sockets before the single bolting unit is engaged. These preliminary actions pre-establish the correct spatial relationship between components, ensuring that when the single bolting unit is installed, it can securely couple all connectors and sockets with the required precision.
Solution Approach 2:
The patent introduces intermediary guide elements (guide holes, guide pins) that act as mediators between the single bolting unit and the multiple connectors/sockets. These intermediary features ensure accurate positioning and alignment, bridging the gap between the simplified single-bolting design and the requirement for high coupling accuracy.
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 enables rapid, accurate, and cost-effective coupling and decoupling of connectors and sockets within a compact space, reducing manufacturing costs and improving maintainability, while ensuring precise alignment and reducing wear on components.
Implementation Method 1
The coupling bolts 40 and the coupling nuts 42 cause the connectors 32 of the lower cover 30 to move upward or downward in response to the worker's operation, thereby coupling or decoupling the connectors 32 and the sockets 12
Data Source
AI summary
A junction box includes a main body in which circuit components are installed, a lower cover configured to cover a lower portion of the main body, one or more sockets installed on a lower surface of the main body, one or more connectors installed in the lower cover and configured to be coupled to the sockets, a single coupling bolt installed in the main body, and a single coupling nut installed in the lower cover and threadedly coupled to the coupling bolt. When rotationally operating the single coupling bolt, the main body is configured to move up or down with respect to the lower cover so that the sockets are coupled to or decoupled from the connectors while making up/down movement with respect to the connectors.