Integrated Power Distribution Box With Merged Fuse And PCB Architecture
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power distribution systems in vehicles lack an integrated and efficient solution for supporting multiple electrical components, including high current fuses, which can lead to complexity and potential electrical safety issues.
Innovation Solution
An integrated power distribution box design featuring a printed circuit board (PCB) with a master fuse and high current fuses, coupled with an intermediate and lower housing, along with connectors and fasteners, to provide a structured and safe electrical connection system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple electrical components including high current fuses are supported in existing power distribution systems, then the electrical functionality is provided, but the system complexity increases and electrical safety issues arise
Solution Approach 1:
The patent combines multiple electrical components (fuses, relays, circuit breakers, control units) into a single integrated power distribution box. The housing integrates mounting structures for high current fuses, low current fuses, relays, and electronic control units, along with bus bars and terminals, all within one unified structure. This merging approach provides complete electrical functionality while reducing overall system complexity compared to distributed arrangements.
Solution Approach 2:
The power distribution box serves multiple functions within a single device: it provides high current distribution through dedicated fuse holders and bus bars, low current distribution through terminal blocks, relay control functions, electronic monitoring and control via integrated control units, and structural support for all components. This multi-functionality eliminates the need for separate distributed systems for each function.
2Adaptability or versatility
If multiple electrical components are supported in existing power distribution systems, then electrical distribution is achieved, but electrical safety issues arise
Solution Approach 1:
The patent implements specialized local structures for different electrical safety requirements: dedicated high current fuse holders with appropriate clearance and creepage distances for high current protection, isolated terminal blocks for low current circuits, separated mounting areas for relays and control units, and grounded metal bus bars. Each component type has its own optimized local environment for safety.
Solution Approach 2:
The integrated housing and structural framework act as intermediaries that provide physical separation, insulation, and grounding pathways between different electrical components. The housing structure includes integrated mounting structures that mediate the spatial relationships between high current and low current components, preventing electrical interference and safety hazards.
3Reliability
If an integrated power distribution box is designed with PCB, master fuse, and multiple fuses, then electrical safety and reliability are enhanced, but the device complexity increases
Solution Approach 1:
The patent segments the power distribution function into distinct hierarchical levels: master fuse for main circuit protection, high current fuses for high power circuits, low current fuses for control circuits, and electronic control units for monitoring. Each segment handles specific electrical characteristics and safety requirements, making the overall complex system manageable through functional segmentation.
Solution Approach 2:
The design implements nested structures where the PCB is mounted within the housing, relay assemblies are nested within the housing structure, fuse holders are integrated into the housing, and terminal blocks are mounted on the housing interior. This nested arrangement consolidates multiple components into a compact integrated unit, enhancing safety through unified structure while managing complexity through organized nesting.
Data Source
AI summary
An integrated power distribution box including an upper level assembly including a printed circuit board comprising at least one electrical component, a lower housing configured to receive at least a portion of the printed circuit board, an intermediate housing configured to be coupled with at least one fuse, a master fuse electrically coupled to the printed circuit board, a lower level assembly including at least one connector corresponding to at least one of the master fuse, the at least one electrical component, and the at least one fuse.