Electrical Unit Bushing for Force Distribution
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Solution Overview
Problem
Existing electrical units, such as power distribution boxes, are complex and may apply unnecessary forces to components, leading to potential damage and insufficient functionality.
Innovation Solution
The electrical unit design includes a housing with multiple members, a circuit board, and a fastener system with a bushing that distributes forces evenly across the components, preventing excessive force on the circuit board and reducing the risk of damage during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional fastening system is used to secure the circuit board in the electrical unit housing, then the circuit board is held firmly in place, but excessive force is applied to the circuit board during assembly, creating risk of damage
Solution Approach 1:
A bushing is introduced as an intermediary component between the fastener and the circuit board. The bushing receives the fastener and distributes the clamping force, preventing direct application of excessive force to the circuit board while still achieving secure fastening. The bushing acts as a force-distributing mediator that decouples the fastening function from the circuit board.
Solution Approach 2:
The fastening function is segmented into separate components: the fastener, the bushing, and the circuit board mounting structure. By dividing the fastening system into these independent elements, the force application path is separated from the circuit board, allowing the bushing to absorb and distribute assembly forces independently.
2Device complexity
If the circuit board is directly integrated into the housing structure for simplified assembly, then manufacturing complexity is reduced, but the circuit board becomes vulnerable to damage from housing assembly forces
Solution Approach 1:
The bushing serves as a protective intermediary between the housing structure and the circuit board. It isolates the circuit board from housing assembly forces while maintaining structural integration, allowing the circuit board to be securely mounted without direct exposure to housing-level mechanical stresses.
3Device complexity
If a simplified fastening system without additional components is used, then device complexity is minimized, but force distribution is insufficient, leading to potential circuit board damage
Solution Approach 1:
The bushing performs multiple functions simultaneously: it acts as a structural support element, a force-distributing component, a protective barrier for the circuit board, and a mounting feature for the fastener. This multi-functionality justifies the addition of the single component while achieving comprehensive force management.
Data Source
AI summary
An electrical unit may include an electrical unit housing having a first housing member, a second housing member, and/or a third housing member; a circuit board that may be disposed at least partially in the electrical unit housing; a fastener that may be disposed at least partially in the first housing member, the second housing member, the third housing member, and/or the circuit board; and/or a bushing that may be disposed at least partially in the first housing member, the second housing member, and/or the circuit board. The fastener may be disposed at least partially in the bushing.