Relay Terminal Drooping Structure for Junction Box Waterproofing

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Solution Overview

Problem

Conventional relay modules in electrical junction boxes are prone to water ingress, which can lead to short circuits due to gaps between the relay main body and the holding member, compromising the waterproofing and electrical reliability.

Innovation Solution

The assembly structure includes a component main body with lead terminals that droop along the side surfaces, housed within a member with insulating features and a housing chamber configuration, where insulating members are placed along the side surfaces to extend the short circuit distance and prevent water transmission between lead terminals, and a cover member is used to enhance waterproofing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the relay main body is brought into contact with end faces of the holding member to prevent water entry, then waterproofing is improved, but any slight gap formed allows water to enter and contact lead terminals causing short circuits

Engineering Contradiction:

ImprovewaterproofingVSAvoidwater ingress

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A resin layer is introduced as an intermediary substance between the lead terminals and the environment. This resin layer fills gaps and surrounds the lead terminals, preventing water from contacting them even when gaps exist between the relay main body and holding member end faces.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The resin layer acts as a flexible protective shell that conforms to the lead terminals and fills irregular gaps. This thin film structure provides waterproofing without requiring precise mechanical fits between rigid components.

Inventive Principle:

Principle #30Flexible shells and thin films

2Volume of moving object

If lead terminals are arranged closely to reduce space, then compactness is improved, but the risk of short circuit between neighboring lead terminals increases

Engineering Contradiction:

Improvespace occupancyVSAvoidshort circuit prevention

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The resin layer serves multiple functions simultaneously: it anchors the lead terminals in place, provides electrical insulation between neighboring terminals, and prevents water ingress. This merging of functions allows close terminal arrangement without increasing short circuit risk.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The use of resin material combines mechanical anchoring function with electrical insulation properties. This composite approach allows lead terminals to be arranged closely while maintaining both structural integrity and electrical isolation.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS9509079B2Assembling structure of electronic component, electrical junction box, and electronic component

Publication Date: 2016.11.29 YAZAKI CORP

AI summary

An assembling structure of an electronic component includes an electronic component including a component main body having a plurality of lead terminals protruding from side surfaces of the component main body, and a housing member in which the electronic component is inserted and accommodated and which holds a plurality of terminal fittings connected to the lead terminals. Each lead terminal includes a base end protruding from at least one side surface of the component main body and a connecting portion which is connected to the base end and which droops along the side surface, and the plurality of lead terminals are provided to be protruded from at least one side surface of the component main body in the width direction of the side surface. The side surface of the component main body is provided with an insulating member.