Junction Block Inner Cover Stiffness for PCB Protection
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Solution Overview
Problem
Conventional junction blocks with bus bars omitted compromise the stiffness of printed circuit boards, risking damage from applied stress such as bending stress.
Innovation Solution
A junction block design featuring a printed circuit board with a distribution wiring circuit, a fuse block, a connector block, and an inner cover providing stiffness, where the fuse and connector blocks are fixed to the inner cover through T-shaped or L-shaped projections and corresponding holes, avoiding direct stress on the printed circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If bus bars are omitted and replaced with other components, then device complexity is reduced, but stiffness of the printed circuit board deteriorates
Solution Approach 1:
The invention divides the support function into multiple segments: the inner cover provides primary stiffness, while the fuse block and connector block act as additional support segments. This segmented approach replaces the single rigid bus bar structure with distributed support elements, reducing complexity while maintaining overall stiffness.
Solution Approach 2:
The inner cover serves as an intermediary element that provides stiffness to the assembly without requiring rigid bus bars. By fixing the fuse block and connector block to the inner cover, the intermediary structure transfers and distributes stresses, protecting the printed circuit board while eliminating the need for complex bus bar wiring.
2Ease of manufacture
If bus bars are omitted, then ease of manufacture is improved, but reliability of the printed circuit board deteriorates
Solution Approach 1:
The inner cover is designed beforehand to provide cushioning and stress distribution support. By pre-configuring the inner cover with appropriate stiffness and the fixing parts (projections and holes) for the fuse and connector blocks, the structure prepares advance protection against bending stresses that might otherwise damage the printed circuit board, ensuring reliability without complex bus bars.
3Strength
If the assembly is fixed with screws, then strength of connection is improved, but ease of operation deteriorates
Solution Approach 1:
The invention extracts the fastening function from complex screw connections and implements it through simple projection-hole engaging parts. The T-shaped or L-shaped projections on the fuse block and connector block mate with corresponding holes in the inner cover, providing adequate connection strength while enabling easy assembly and disassembly operations.
Solution Approach 2:
The fixing parts are designed to be self-aligning and self-locking. The projections automatically engage with the holes when components are brought together, and the T-shaped or L-shaped geometry provides inherent positioning and retention without requiring additional fastening operations. This self-service mechanism maintains connection strength while dramatically improving ease of operation.
Data Source
AI summary
A junction block includes: a printed circuit board; a fuse block; connector blocks; and an inner cover for providing a stiffness to an assembly integrating the printed circuit board, the fuse block and the connector block; and fixing parts for fixing the fuse block and the connector blocks to the inner cover together. The fuse block and the connector blocks are fixed to the inner cover through the fixing parts.