LED Power Supply Junction Box Waterproofing and Wiring Flexibility

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Solution Overview

Problem

Existing LED power supply junction boxes often require separate installation of components, lack waterproofing, and have limited wiring space, leading to installation difficulties and increased maintenance costs.

Innovation Solution

An integrated LED power supply junction box design featuring a circular groove for water drainage, a movable baffle for adjustable wiring spaces, and a hinge structure for improved accessibility, along with small circular through holes for control devices, providing a waterproof and flexible solution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If LED power supply and junction box are installed separately, then installation flexibility is improved, but installation complexity and maintenance cost increase

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidinstallation complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent integrates the LED power supply and junction box into a single unified structure. The power supply is installed within the junction box housing, combining two previously separate components into one integrated unit. This reduces the number of separate installation steps and simplifies maintenance operations while maintaining installation flexibility.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The junction box is designed to serve multiple functions simultaneously: it acts as both a wiring junction box and a housing for the LED power supply. This multi-functional design eliminates the need for separate installations of power supply and junction box, reducing overall system complexity while preserving operational flexibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Device complexity

If traditional junction box design is used, then structural simplicity is maintained, but waterproofing performance is insufficient

Engineering Contradiction:

Improvestructural simplicityVSAvoidwaterproofing performance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The junction box is divided into multiple sealed compartments using internal partitions. These partitions create independent sealed spaces that prevent water penetration between different functional areas. The circular grooves further segment the sealing paths, creating multiple barriers against water ingress while maintaining overall structural simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The circular grooves and drainage holes, which could potentially be seen as structural weaknesses, are actually designed to channel and drain water away from critical components. By providing controlled water pathways, the design converts potential water intrusion into a beneficial drainage system that protects internal components.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If fixed wiring space design is used, then manufacturing simplicity is maintained, but adaptability to different wiring needs is reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidwiring space adaptability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The baffle structure is designed to be movable rather than fixed, allowing the wiring space to be dynamically adjusted according to different installation requirements. The baffle can be repositioned along guide rails or slots, enabling flexible configuration of wire routing paths while maintaining a relatively simple overall manufacturing process.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The adjustable baffle system is nested within the junction box structure, with the baffle fitting into designated slots or channels. This nested design allows for movement and adjustment without adding significant structural complexity, enabling adaptability while keeping manufacturing relatively simple.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Strength

If upper cover is sealed tightly, then structural integrity is improved, but water drainage capability is reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidwater drainage capability

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The upper cover incorporates flexible sealing elements such as rubber gaskets or membrane structures that can deform to accommodate drainage requirements. These flexible sealing components maintain structural integrity and waterproofing while allowing controlled water passage through integrated drainage channels, balancing strength and drainage capability.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS11489322B2LED power supply integrated junction box

Publication Date: 2022.11.01 ZHUHAI SHENGCHANG ELECTRONICS CO LTD

AI summary

Provided is an LED power supply integrated junction box, which includes a main body and a bottom cover. One side of an inner wall of the main body is connected with multiple positioning hollow columns. A partition is fixedly connected to the middle of the main body. Two small circular through holes are defined in one side of the partition. The opposite surfaces of the partition and the inner wall of the main body are each fixedly connected with multiple clamping grooves.