Automotive Junction Box Stepped Cover for Compact Waterproofing
Solution Overview
Problem
Conventional electrical junction boxes in automobiles face challenges in preventing interference between the inner wall of the rotating upper cover and the outer wall of the box body, leading to increased size and compromised waterproofing, as they require large clearances to prevent water infiltration.
Innovation Solution
The design features double wall portions with specific positioning of projecting end surfaces, where the outer wall of the box body is inside the upper cover, and the inner wall of the box body is higher than the upper cover's inner wall, preventing interference and enhancing waterproofing by directing water away from the interior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a large clearance is formed between the inner wall of the upper cover and the outer wall of the box body to prevent interference during rotation, then interference is prevented, but the size of the electrical junction box increases
Solution Approach 1:
The patent applies dimensionality change by forming the inner wall of the upper cover with a stepped structure that has different heights in different regions. Specifically, the inner wall has a first height in the rotation direction and a second height in the width direction, creating a multi-level configuration. This allows the inner wall to clear the outer wall of the box body during rotation without requiring excessive clearance, thus preventing interference while maintaining a compact overall size.
2Ease of operation
If a large clearance is formed between the inner wall of the upper cover and the outer wall of the box body to prevent interference during rotation, then interference is prevented, but waterproofing is compromised
Solution Approach 1:
The stepped structure of the inner wall with different heights in different regions creates multiple levels that effectively block water infiltration paths. The varying heights form a barrier that prevents water from reaching through the clearance between the upper cover and box body, thus maintaining waterproofing while allowing sufficient clearance for rotation.
Solution Approach 2:
The inner wall is segmented into different height levels (first height and second height) in different regions. This segmentation creates multiple barriers against water infiltration while allowing the structure to accommodate the rotation movement. The segmented design enables the clearance to be distributed and controlled at different locations, preventing water infiltration without requiring uniformly large clearance throughout.
3Ease of operation
If the inner wall of the upper cover is formed with a clearance from the outer wall of the box body to prevent interference, then rotation is enabled, but the size of the electrical junction box inevitably increases
Solution Approach 1:
The patent forms the inner wall with a stepped structure having different heights in different regions (first height in rotation direction, second height in width direction). This dimensional variation allows the inner wall to maintain adequate clearance for rotation and attachment operations while minimizing the overall volume increase of the electrical junction box.
Data Source
AI summary
An electrical junction box in which the interference between an inner wall of a rotating upper cover and an outer wall of a box body can be more reliably prevented and a waterproof property can be secured, while also meeting the demand for reduction in size of the electrical junction box. In a state in which an upper cover is attached to a box body, on one end side of the box body and one end side of the upper cover, an outer wall of the box body is located on an inner side with respect to an outer wall of the upper cover, an inner wall of the upper cover is located on an inner side with respect to the outer wall of the box body, and an inner wall of the box body is located on an inner side with respect to the inner wall of the upper cover.