Junction Box Over-Travel Spring Mechanism
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Solution Overview
Problem
Junction box assemblies face challenges in securely fastening high-power electrical components while allowing for relative motion to prevent electrical arcing and external damage, particularly in vehicles requiring high voltage and current distribution.
Innovation Solution
The junction box assembly incorporates a housing member with a component receptacle and a spring post that secures electrical components by allowing barbs to seat within locking openings, enabling resilient movement and stabilization, thus preventing over-travel and ensuring secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the electrical component is securely fastened to prevent movement, then connection stability is improved, but the ability to accommodate insertion over-travel is reduced
Solution Approach 1:
The locking tab is designed as a resilient (flexible) element that can dynamically adjust its position. During insertion, the tab flexes to accommodate over-travel beyond the locked position, then springs back to maintain secure engagement. This dynamic behavior allows the system to be both stable when locked and adaptable during insertion.
Solution Approach 2:
The resilient locking tab acts as a pre-designed cushioning element that absorbs excess insertion force before it can damage the rigid electrical component or housing. The tab's elasticity provides a compliant interface that prevents hard impacts while maintaining secure connection.
2Strength
If the locking tab is made rigid to ensure secure locking, then locking strength is improved, but the ability to allow relative motion is reduced
Solution Approach 1:
The locking tab transitions from a static rigid element to a dynamic resilient element. It maintains rigidity when engaged with the barb to provide strong locking, but flexes when force is applied during insertion to allow over-travel. The material and geometry are designed to provide appropriate stiffness in the locked state while maintaining elasticity for insertion accommodation.
3Manufacturing precision
If the component receptacle is designed to prevent over-travel, then connection precision is improved, but the ability to allow insertion motion is reduced
Solution Approach 1:
The resilient locking tab is positioned to engage the barb before the electrical component can contact the housing surface. This pre-engagement cushions the insertion process, allowing the component to travel slightly beyond the precise locked position without causing damage, then maintains precise positioning through the elastic retention of the tab.
Solution Approach 2:
The resilient locking tab serves as an intermediary element between the rigid electrical component and the rigid housing. It mediates the insertion process by providing a compliant interface that allows motion during insertion while maintaining precision in the locked state, eliminating the need for the component to precisely stop at the locked position.
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
This design effectively secures high-power electrical components, prevents electrical arcing, and allows for relative motion to accommodate insertion over-travel, enhancing the reliability and safety of electrical connections in high-voltage applications.
Implementation Method 1
A junction box assembly is disclosed including a housing member and an electrical component. The housing member includes a housing surface. A component receptacle having a pair of opposing sidewalls coupled to the housing surface. Each sidewall has a locking opening disposed therein and each locking opening defines a locking surface. A post is arranged within the component receptacle and extends from the housing surface for a predetermined distance to a post surface. The electrical component is received in the component receptacle and has a component surface adjacent the post surface and a barb received in each locking opening. The post applies a force to the electrical component for retaining the barb against the locking surface.
Data Source
AI summary
A junction box assembly includes a housing member and an electrical component. The housing member has a housing surface and a component receptacle having a pair of opposing sidewalls coupled to the housing surface. Each sidewall has a locking opening disposed therein and each locking opening defines a locking surface. A post is arranged within the component receptacle and extends from the housing surface for a predetermined distance to a post surface. The electrical component is received in the component receptacle and has a component surface adjacent the post surface and a barb received in each locking opening. The post applies a force to the electrical component for retaining the barb against the locking surface.