Electric Connection Box Insulating Ribs on Wiring Board

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Solution Overview

Problem

Conventional electric connection boxes require multiple covers with different insulating rib arrangements to accommodate various circuit constructions, leading to increased production costs and mold complexity.

Innovation Solution

The electric connection box design features a single common cover with a first wiring board having molded insulating ribs and a second wiring board with through holes, allowing the ribs to project through the holes to insulate circuits, eliminating the need for insulating ribs on the cover and reducing mold and production costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If insulating ribs are molded integrally on the cover to insulate circuits, then insulation between circuits is achieved, but the cover cannot be used for different circuit constructions and production cost increases

Engineering Contradiction:

Improveinsulation between circuitsVSAvoidcover compatibility with different circuit constructions

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The insulating rib is separated from the cover and integrated into the wiring board instead. This segmentation allows the cover to remain universal while the insulating function is provided by the wiring board's insulating ribs that can be positioned according to specific circuit requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of forming insulating ribs on the cover as in conventional designs, the patent inverts the approach by forming insulating ribs directly on the wiring board. This inversion allows the cover to maintain commonality across different circuit constructions while still achieving effective insulation.

Inventive Principle:

Principle #13The other way round (Inversion)

2Adaptability or versatility

If multiple kinds of covers with different insulating rib arrangements are prepared for different circuit constructions, then adaptability to various wiring boards is achieved, but production cost and mold complexity increase

Engineering Contradiction:

Improvecover compatibility with different wiring boardsVSAvoidproduction cost and mold complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The cover is designed as a universal component that can be used with multiple kinds of wiring boards having different circuit constructions. The adaptability is achieved not through variations in the cover itself, but through the ability to form insulating ribs and through holes on different wiring boards to match their specific insulation requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The insulating structure is segmented from the cover and transferred to the wiring board. This allows the cover to maintain a single standardized design while the insulating features are customized per wiring board type, reducing mold complexity and production costs.

Inventive Principle:

Principle #1Segmentation

3Reliability

If insulating ribs are formed on the cover for each circuit construction, then proper insulation is achieved, but material usage and production cost increase

Engineering Contradiction:

Improvecircuit insulationVSAvoidmaterial usage for cover production

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The insulating rib feature is extracted from the cover and transferred to the wiring board. This extraction eliminates the need to produce different cover variants with integrated insulating ribs, thereby reducing material consumption for cover production while maintaining effective insulation through the wiring board's insulating ribs.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS7179097B2Electric connection box having an improved insulating structure

Publication Date: 2007.02.20 YAZAKI CORP

AI summary

An electric connection box includes a first wiring board having first insulating ribs formed thereon, and a second wiring board having through hole portions (for respectively passing the first insulating ribs therethrough) formed respectively at regions of insulating of circuits from each other. The first wiring board and the second wiring board are stacked together, and are received within covers. The first insulating ribs of the first wiring board project respectively through the hole portions of the second wiring board to insulate the circuits of the second wiring board from each other.