Electrical Junction Box Snap-Fit PCB Fixation Without Protective Covers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for assembling electrical junction boxes require time-consuming attachment and removal of protective covers, increasing working and component costs while attempting to protect electronic components during circuit board fixation.
Innovation Solution
An electrical junction box design featuring a circuit board with a slit and penetration holes, and a board connector with a positioning rib and elastically deformable projecting portions that allow for easy fixation without screws, using a support structure to align and secure the circuit board during soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective cover is attached to the circuit board to protect electronic components during screwing, then the electronic components are protected from damage, but the assembly process becomes time-consuming and requires additional attachment and removal steps
Solution Approach 1:
The patent removes the protective cover from the assembly process entirely by designing the circuit board with built-in protective features. The recessed mounting surfaces and positioning structures provide inherent protection for electronic components during the screwing operation, eliminating the need for separate protective covers and their attachment/removal steps.
Solution Approach 2:
The circuit board is designed with self-protecting features through its structural design. The recessed mounting surfaces and integrated positioning structures automatically protect electronic components during assembly without requiring external protective elements, making the protection function inherent to the board itself.
2Strength
If screws are used to fix the circuit board to the board connector, then the fixation is secure and reliable, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent replaces the screw-based mechanical fastening system with a snap-fit mechanical system. The projection on the board connector engages with the recess on the circuit board, providing secure fixation through elastic deformation and geometric interlocking rather than threaded fasteners, thereby simplifying the assembly process.
Solution Approach 2:
The patent changes the mechanical engagement parameters from threaded connection to elastic snap-fit connection. The projection is designed with specific elastic properties and geometric dimensions that enable reliable fixation through deformation and interlocking, replacing the screw mechanism with a more efficient elastic mechanical system.
3Reliability
If a protective cover is used to protect electronic components, then component safety is improved, but additional components and costs are required
Solution Approach 1:
The patent merges the protective function into the circuit board structure itself. The recessed mounting surfaces and integrated positioning structures that serve the primary function of mounting also provide protection for electronic components, combining multiple functions into a single integrated design rather than using separate protective components.
Solution Approach 2:
The circuit board structure is designed to serve multiple functions simultaneously. The recessed mounting surfaces not only provide precise positioning and mounting but also protect electronic components during assembly. The positioning structures serve both alignment and protection purposes, making the design multi-functional and eliminating the need for separate protective components.
4Manufacturing precision
If precise positioning structures are added to align the circuit board with the board connector, then alignment precision is improved, but the device complexity increases
Solution Approach 1:
The patent applies positioning features at specific local areas of the circuit board and board connector rather than throughout the entire structure. The recess and projection are located at critical positions to provide precise alignment, concentrating the positioning function in specific locations rather than requiring complex overall structural design.
Solution Approach 2:
The positioning structures utilize asymmetric geometric features (the recess and its corresponding projection) to achieve precise alignment. The asymmetric shapes provide unique mating characteristics that ensure correct orientation and positioning, simplifying the alignment process compared to symmetric or complex positioning systems.
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
Facilitates efficient assembly by reducing the need for screws, lowering costs, and effectively protecting electronic components by ensuring precise alignment and secure fixation of the circuit board to the board connector.
Implementation Method 1
a plurality of divided pieces circumferentially divided by a plurality of slits extending toward an axis from an outer peripheral surface so as to be formed individually elastically deformable in a radial direction
Data Source
AI summary
In an electrical junction box, a positioning rib is inserted into a slit in an abutment state in which a circuit board is in abutment with a positioning surface. Projecting portions of a housing are formed projecting from support portions toward the circuit board, and are inserted through penetration holes of the circuit board. Each projecting portion includes a plurality of divided pieces formed elastically deformable in a radial direction. The divided piece has a regulation portion that regulates movement in an insertion and removal direction of the circuit board between the regulation portion and the support portion.