Two-Piece Junction Box Assembly for Lower Mold Cost
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Solution Overview
Problem
The existing connection boxes for building construction, such as those described in application FR-2997431, require significant investment for mold manufacturing due to complex structures and lack efficient logistics and waste reduction.
Innovation Solution
A connection box designed as an upper half-box assembled with a lower half-box, both molded in one piece, with assembly means including peripheral walls, hooks, and guide pins, allowing for easy assembly and stacking, reduced mold investment, and simplified logistics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-piece molded junction box is used, then the structural integrity is improved, but the mold investment cost increases significantly
Solution Approach 1:
The junction box is divided into two separate half-boxes (first half-box and second half-box) that are molded independently using simpler molds, then assembled together. This segmentation allows each half-box to be manufactured with less complex molds, reducing investment cost while maintaining the integrity of the final assembled structure.
2Strength
If a complex single-piece molded box is used, then the mechanical strength is improved, but the device complexity increases
Solution Approach 1:
The complex single-piece box is segmented into two simpler half-boxes. Each half-box has a simpler individual structure, but when assembled together with assembly means (protrusions and recesses), they form the complete functional junction box, reducing the complexity of individual manufacturing while achieving the required overall strength.
Solution Approach 2:
Two separate half-boxes are merged together through assembly means (protrusions fitting into recesses) to form the complete junction box. This merging combines the simplicity of individual half-box manufacturing with the strength of a unified structure, achieving mechanical integrity without the complexity of a single-piece mold.
3Productivity
If identical half-boxes from the same mold are used, then the logistics efficiency is improved, but the assembly precision requirements increase
Solution Approach 1:
The junction box is segmented into two identical half-boxes manufactured from the same mold, enabling standardized production and efficient logistics. The identical design allows for bulk manufacturing and storage, improving productivity while the segmentation into manageable halves facilitates handling and transport.
Solution Approach 2:
While the half-boxes are identical in overall form, asymmetric features such as protrusions and recesses are introduced at specific locations. These asymmetric assembly means ensure precise alignment and fitting during assembly, compensating for the need for high precision while using identical base molds for both halves.
Data Source
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AI summary
The invention relates to a junction box comprising at least a lid, a bottom and side walls comprising lids (22). The box is in particular in the form of an upper half-box assembled with a lower half-box, the upper half-box and the lower half-box comprising assembly means, the upper half-box and the lower box each being molded in a single block, the upper and respectively lower half-box comprising the cover or respectively the bottom fixed to the side half-walls (4, 5, 6, 7), the side half-walls of the upper half-box and respectively of the lower half-box being also fixed together in pairs.