Washer-Retaining Bracket Rib Configuration for Junction Box Stability

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Solution Overview

Problem

Existing bracket configurations for electric junction boxes face issues with washer deviation or disconnection due to clearance gaps and require excessive force for assembly, leading to deformation and instability during screw tightening or fastening.

Innovation Solution

A washer-retaining bracket configuration featuring a rib along the edge of the opening to prevent washer deviation, a circular depression for the washer, and a guide rail with a locking projection to securely engage the washer case, allowing for slidable fit and reduced assembly force while preventing deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the washer case is slidably fit into the bracket to retain the washer, then the washer is prevented from deviation or disconnection, but a relatively great force is needed for assembly and the washer case may undergo deformation

Engineering Contradiction:

Improvewasher retention stabilityVSAvoidassembly force required

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The opening edge is segmented into multiple ribs that are distributed around the perimeter. Each rib independently engages with the bracket, distributing the assembly force across multiple contact points rather than requiring concentrated force at a single location. This segmentation allows the washer case to be fitted into the bracket with reduced force while maintaining reliable washer retention.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The ribs are positioned at specific locations around the opening edge where engagement with the bracket is most effective. The local structural quality is enhanced at these rib locations to provide precise engagement points that guide the washer case into the bracket smoothly, reducing the overall assembly force needed while ensuring stable washer retention.

Inventive Principle:

Principle #3Local quality

2Reliability

If the washer case is slidably fit into the bracket, then the washer is retained, but the clearance gap between the washer case and bracket may cause the washer to be disconnected or dropped off

Engineering Contradiction:

Improvewasher retentionVSAvoidclearance gap control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The ribs act as intermediary elements between the washer case opening edge and the bracket. These ribs fill and bridge the clearance gap by engaging with the bracket structure, preventing the washer from deviating or disconnecting through the gap. The ribs serve as a mechanical mediator that eliminates the harmful effect of the clearance gap while maintaining the slidable fit configuration.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The ribs extend in a direction perpendicular to the main sliding fit direction, creating a three-dimensional engagement structure. This dimensional addition allows the ribs to engage with the bracket in a manner that prevents washer deviation in multiple directions, effectively controlling the clearance gap through spatial engagement rather than relying solely on precise dimensional tolerances.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Stability of the object's composition

If a locking hole of the washer case is forced to mate with a locking projection of the bracket, then the washer case is locked in place, but the washer case may run on the locking projection thereby enlarging in radial direction and undergoing deformation

Engineering Contradiction:

Improvewasher case positioningVSAvoidwasher case radial deformation

Core Design Contradiction:

Stability of the object's compositionVSShape

Solution Approach 1:

The ribs are positioned and configured in advance to guide the washer case into proper alignment with the bracket before the locking engagement occurs. This preliminary guiding action ensures that the locking hole mates smoothly with the locking projection without forcing or running on the projection, preventing radial deformation while achieving stable positioning.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The rib structure provides a cushioning effect during the assembly process by distributing engagement forces and absorbing shocks that would otherwise be transmitted directly to the locking hole and projection interface. This beforehand cushioning prevents the washer case from running on the locking projection, eliminating radial enlargement and deformation while ensuring stable positioning.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS9227578B2Washer-retaining bracket configuration

Publication Date: 2016.01.05 YAZAKI CORP

AI summary

The present invention provides a bracket configuration for retaining a washer within a washer case which has an opening for inserting the bracket therethrough so that the washer case is mounted to the bracket from above the washer. The bracket configuration specifically includes a hole configured to dispose the washer thereon and insert a bolt therethrough, and a rib formed along an edge of the opening so as to prevent or protect the washer from deviation or disconnection via a clearance gap created between the opening and the bracket.