Recessed Junction Box Keying for Protected Terminal Alignment
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Solution Overview
Problem
Conventional junction box assemblies have key features that protrude outwardly, making them susceptible to damage during shipment and requiring protective packaging, which increases costs and complexity.
Innovation Solution
The junction box assembly features recessed key features that are shaped differently for each terminal, allowing secure seating and protection from accidental drops by being recessed within the outer wall, eliminating the need for additional protective packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If key features protrude outwardly from the outer wall to ensure proper terminal alignment, then terminal positioning accuracy is improved, but the key features become susceptible to damage during shipment requiring protective packaging
Solution Approach 1:
The patent inverts the conventional design by recessing the key features into the outer wall instead of protruding them outward. This inversion maintains the terminal positioning function while protecting the key features from damage during shipment, eliminating the need for protective packaging.
Solution Approach 2:
The patent transitions the key features from a protruding configuration (extending outward from the surface) to a recessed configuration (indented into the surface). This dimensional change preserves the alignment function while adding protective coverage during handling and shipment.
2Object-affected harmful factors
If protective packaging is added to protect protruding key features during shipment, then damage protection is improved, but packaging complexity and costs increase
Solution Approach 1:
Instead of adding protective packaging around protruding key features, the patent inverts the design to recess the key features into the outer wall. This eliminates the need for additional protective packaging while maintaining damage protection, thereby reducing packaging complexity and costs.
3Object-affected harmful factors
If recessed key features are used to protect from damage during shipment, then damage susceptibility is reduced, but terminal alignment precision may be compromised
Solution Approach 1:
The patent applies local quality by creating specifically shaped recesses within the outer wall that precisely accommodate corresponding terminals. Each recess is designed with dimensions and geometry that ensure proper terminal alignment while maintaining the protective recessed configuration.
Solution Approach 2:
The patent inverts the conventional protruding design to recessed features, but compensates for any potential alignment loss by designing the recesses with precise dimensions and shapes that actively guide terminal positioning, thereby maintaining alignment precision.
Data Source
AI summary
A junction box is dimensioned to accommodate electronic components, and receives a plurality of terminals, including a distal end shaped differently from each other. The junction box includes an outer wall and a bottom wall. The outer wall extends upwardly from a peripheral edge of the bottom wall. The bottom wall and the outer wall are dimensioned to form a plurality of recesses spaced apart from each other and forming a key feature that corresponds in shape to one of the plurality of terminals. As such, each of the plurality of terminals are designed to be seated within a predetermined key feature. Further, as the key features are recessed with respect to the outer wall, the key features are protected from damage as a result of an accidental drop or during shipment.