Resin Bracket Positioning for Junction Box Rotation
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Solution Overview
Problem
The existing electrical junction boxes face issues with the metallic bracket rotating and loosening due to dimensional mismatches between metallic and resin materials, leading to a lack of precise positioning and strong securing function when attached to a vehicle body.
Innovation Solution
An electrical junction box with a bracket made of resin molding material, featuring positioning pins and holes for precise alignment, combined with a bolt and nut system to prevent rotation and ensure secure attachment, along with reinforcing features to match the strength of metallic brackets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metallic bracket is fixed on a resin molding material securing section using a bolt and nut, then the bracket can be attached to the electrical junction box, but dimensional mismatches occur due to different materials causing movement and rotation
Solution Approach 1:
The bracket is made from resin molding material, the same material as the electrical junction box casing. This homogeneity eliminates dimensional mismatches and movement issues that occur with metallic brackets on resin sections, while maintaining adequate securing strength through integrated positioning pins and holes.
Solution Approach 2:
Positioning pins and holes are introduced as intermediary elements between the bracket and securing section. These pins fit into holes to prevent rotation and movement, mediating the connection between the bracket and electrical junction box to achieve precise dimensional alignment.
2Ease of manufacture
If a metallic bracket is positioned and then fastened with a bolt, then the bracket can be secured to the electrical junction box, but the bracket rotates about the bolt hole requiring correction
Solution Approach 1:
Positioning pins are pre-installed on the bracket before attachment to the electrical junction box. These pins preliminarily establish the correct position and orientation, preventing rotation during the subsequent bolting process and eliminating the need for post-assembly correction.
3Reliability
If a bracket is attached to the electrical junction box, then the junction box can be secured to the vehicle body, but the bracket can readily rotate during attachment causing loosening
Solution Approach 1:
The bracket uses composite construction combining resin molding material with integrated positioning features (pins and holes). This composite design provides both the securing function and rotational stability, preventing loosening during vehicle body attachment while maintaining ease of manufacture.
Data Source
AI summary
A bracket secured to a vehicle body is firmly attached to an electrical junction box without causing any loosening. The electrical junction box includes a bracket securing section provided integrally on a casing outer surface and a bracket made of a resin molding material fixed on the bracket securing section by a bolt and a nut. Bolt holes are provided in the bracket securing section and the bracket, respectively. Positioning pins project near the bolt hole in one of the bracket securing section or the bracket. The positioning holes are provided in the other of the bracket securing and the section or bracket to receive the positioning pins. After the positioning pins are fitted in the positioning holes to position and hold the bracket on the bracket securing section, a bolt is inserted into the corresponding bolt holes and is fastened by a nut.