Waterproof Junction Box Wire Cover Step Seal
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Solution Overview
Problem
Conventional wire covers for electrical junction boxes fail to reliably prevent water from entering through electric wires, especially when the number of wires is small, due to design flaws that allow splattered or high-pressure washing water to enter from the bottom, and they often increase costs with additional components or compromise waterproof performance.
Innovation Solution
A waterproof structure featuring a tubular wire cover with a step portion on its rear wall, slidably engaged with the junction box main body, which prevents water entry by directing it downward, eliminating the need for additional waterproof components and reducing manufacturing costs through integral molding with synthetic resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional wire cover without additional waterproof components is used, then the manufacturing cost is reduced and the structure is simplified, but water can enter the junction box through spaces between electric wires and the junction box main body
Solution Approach 1:
The waterproof function is merged into the wire cover itself by forming a step portion as an integral structure during molding. This combines the wire cover's protective function with the waterproof sealing function, eliminating the need for separate waterproof components while maintaining reliable waterproof performance against splattered water and high-pressure washing water
Solution Approach 2:
The step portion changes the geometric parameters of the wire cover structure by creating a protrusion that reduces the gap between the wire cover and junction box main body. This parameter change (adding the step portion) effectively seals the space around electric wires, preventing water entry while keeping the overall structure simple and cost-effective
2Reliability
If a waterproof elastic sheet is added to the wire cover, then waterproof performance is improved, but the number of components increases and manufacturing cost increases
Solution Approach 1:
The waterproof function that previously required a separate elastic sheet component is now merged into the wire cover's integral structure through the step portion. This eliminates the need for additional waterproof components while maintaining effective waterproofing against splattered water and high-pressure washing water
Solution Approach 2:
The waterproof function is extracted from the separate elastic sheet component and integrated directly into the wire cover structure. This extraction eliminates the need for additional components and simplifies the overall structure while maintaining reliable waterproof performance
3Reliability
If a downwardly-slanted waterproof wall with a projected end is provided in the junction box main body, then waterproof performance is improved, but the effectiveness decreases when the number of electric wires is small
Solution Approach 1:
Instead of providing the waterproof structure in the junction box main body (as in conventional designs), the waterproof step portion is inverted and provided on the wire cover itself. This reversal allows the waterproof structure to move with the wire cover, maintaining effective sealing regardless of the number of electric wires or their arrangement
Data Source
AI summary
The waterproof structure of an electrical junction box herein prevents water from entering into the electrical junction box. The electrical junction box includes a main body having a groove formed on an outer wall thereof and a tubular wire cover composed of front and rear split covers. Electric wires are passed downward through the wire cover and fixed to a lower portion of the wire cover using a tape. The wire cover is slidably engaged with the groove of the junction box main body. The waterproof structure includes a step portion as a water stop formed on a rear wall of the wire cover. The rear wall is arranged in contact with or adjacent to a back wall of the groove so that the step portion prevents water from entering into the electrical junction box from bottom along the back wall of the groove through the electric wire.