One-Bolt Junction Box with Central Connector
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Solution Overview
Problem
Conventional junction boxes have complex bolting structures that increase manufacturing costs, are time-consuming to operate, and restrict space for electrical parts, making it difficult to connect three wire harnesses in modern vehicles without increasing the box size.
Innovation Solution
A one-bolt type junction box design with a central connector and guide means, allowing for efficient use of space and accommodating three connectors without size increase, using a single fixing bolt and nut for vertical movement of the main body and sockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple fastening bolts and nuts are installed for each connector, then the connectors can be securely coupled to sockets, but the structure becomes complex and manufacturing cost increases
Solution Approach 1:
Multiple fastening bolts and nuts are merged into a single integrated fastening structure. The single fastening bolt simultaneously engages with multiple connectors through the lower cover, eliminating the need for separate bolt-nut assemblies for each connector. This reduces part count and structural complexity while maintaining secure coupling of all connectors to the sockets.
Solution Approach 2:
The single fastening bolt serves multiple functions: it secures multiple different connectors (side connectors and central connector) to their respective sockets, provides vertical movement control for the entire connector assembly, and enables unified tightening/loosening operation for all connectors simultaneously.
2Reliability
If individual fastening structures are provided for each connector, then each connector can be independently secured, but the work of coupling and separating connectors becomes time-consuming
Solution Approach 1:
The fastening operations for multiple connectors are merged into a single action. By using one fastening bolt that engages all connectors simultaneously, the worker can secure or release all connectors in one tightening or loosening motion, dramatically reducing the time required compared to operating multiple individual fasteners sequentially.
3Reliability
If bolting structures are installed for each connector, then connectors can be firmly attached, but the installation space in connectors and main body is reduced
Solution Approach 1:
The fastening functions for multiple connectors are merged into a single bolt mechanism, eliminating redundant fastening structures. This consolidation frees up significant installation space within the main body and connectors that would otherwise be occupied by multiple separate bolt holes, nut seats, and associated mounting features.
Solution Approach 2:
The unnecessary duplicate fastening components (extra bolts, nuts, and their mounting structures) are extracted/removed from the design. By keeping only the essential single fastening bolt, the patent eliminates excess material and structural elements, thereby increasing the available space for electrical parts and wire harnesses.
4Quantity of substance
If multiple connectors are accommodated in the junction box, then the capacity increases, but the space for terminals and electrical parts is narrowed
Solution Approach 1:
The patent utilizes the vertical dimension by incorporating a lower cover that extends downward from the main body. This allows connectors to be arranged in multiple levels (side connectors in the main body plane and central connector below), effectively increasing connector capacity without consuming additional horizontal space that would be needed for terminals and electrical parts.
Data Source
AI summary
A one-bolt type junction box includes a main body in which electrical parts are installed, a lower cover configured to cover a lower portion of the main body, sockets installed on a lower surface of the main body, side connectors installed in the lower cover so as to be coupled to the sockets, a single fixing bolt installed in the main body, a single fixing nut provided in the lower cover so as to be threadedly coupled to the fixing bolt, a central connector mounted in a central portion of the junction box in which the fixing bolt and the fixing nut are disposed, and a connector seating member in which the central connector is seated. The central connector is configured to be mounted on the lower cover in a state in which the central connector is seated on the connector seating member.