Electric Connection Box Terminal Load Distribution

Solution Overview

Problem

Existing electric connection boxes for automotive vehicles face challenges in alleviating the load on substrate terminals during insertion and removal of electric components, leading to potential damage and increased component count, which complicates manufacturing and costs.

Innovation Solution

An electric connection box design featuring a printed board with a stacked circuit body and insulating plate, where the substrate terminals have a locking portion with a pressing portion integrated into the insulating plate, dispersing the pulling load and reducing the number of components by using the insulating plate to alleviate the load on soldered portions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If substrate terminals are mounted directly on the printed board without holding members, then the number of components is reduced and manufacturing is simplified, but the soldered portions are subjected to large external forces during insertion and removal of electric components

Engineering Contradiction:

Improvenumber of componentsVSAvoidstrength of soldered portions

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The pressing portion is integrated into the insulating plate, merging two functions (insulation and load distribution) into a single component. This eliminates the need for separate holding members while protecting the soldered portions from external forces during connector insertion and removal.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The pressing portion acts as an intermediary element between the connector terminals and the substrate terminals. It distributes the frictional resistance and external forces across a larger area of the insulating plate, preventing direct transmission of stress to the soldered portions.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If holding members are used to support substrate terminals, then the soldered portions are protected from external forces, but the number of components increases and manufacturing efficiency deteriorates

Engineering Contradiction:

Improveprotection of soldered portionsVSAvoidmanufacturing efficiency

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The pressing portion is integrated into the insulating plate, merging two functions (insulation and load distribution) into a single component. This eliminates the need for separate holding members while protecting the soldered portions from external forces during connector insertion and removal.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating plate serves multiple functions: electrical insulation between the printed board and circuit body, structural support, and load distribution through the pressing portion. This multi-functionality eliminates the need for separate holding members and simplifies manufacturing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If holding members are placed on the printed board, then substrate terminals are protected from loads, but the area on the printed board available for use is limited

Engineering Contradiction:

Improveprotection of substrate terminalsVSAvoidavailable printed board area

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

The pressing portion extends in the thickness direction of the insulating plate, utilizing the third dimension (Z-axis) rather than occupying additional area on the printed board surface. This allows load distribution without compromising the available printed board area for circuit traces and components.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The pressing portion is integrated into the insulating plate, merging two functions (insulation and load distribution) into a single component. This eliminates the need for separate holding members while protecting the soldered portions from external forces during connector insertion and removal.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS8378211B2Electric connection box

Publication Date: 2013.02.19 SUMITOMO WIRING SYSTEMS LTD

AI summary

The invention provides an electric connection box having a novel structure in which a load applied to substrate terminals at the time of insertion and pulling out of electric components is alleviated with a small number of components, while the effective utilization of the printed board is realized. A circuit body is stacked on the printed board with an insulating plate interposed therebetween. The substrate terminals are formed so as to project from a surface of the printed board on the side where the circuit body is stacked at portions which are not covered with the circuit body, and each are formed with a locking portion to be placed on the surface of the printed board at a base portion thereof. On the other hand, pressing portions for pressing the locking portions are integrally formed with the insulating plate.