L-Shaped Terminal Vertical Stacking for Junction Box Heat Reduction
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Solution Overview
Problem
The existing electric connecting structures for vehicle-mounted electric junction boxes face increased costs and heat generation due to the length of L-shaped terminals, which also lead to higher costs for terminal materials and heat interference between stacked components.
Innovation Solution
The electric connecting structure features L-shaped terminals assembled to a circuit board with mounting planes arranged in a step-like shape, allowing components to be stacked vertically with each stage displaced inward, reducing terminal length and using low-grade materials to minimize heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If L-shaped terminals are made longer to connect stacked components vertically, then connectivity between components is improved, but material cost and heat generation increase
Solution Approach 1:
The patent transitions from horizontal terminal arrangement to vertical stacking arrangement, utilizing the vertical dimension to stack mounting planes. This allows components to be connected through shorter vertical terminal segments rather than long horizontal terminals, reducing both material usage and heat generation while maintaining connectivity.
Solution Approach 2:
The patent implements nested mounting planes where lower mounting planes are positioned beneath upper mounting planes. The L-shaped terminals nest within the vertical space between these planes, with the horizontal portion connecting to lower planes and the vertical portion reaching upper planes, creating an efficient space-utilizing structure that minimizes terminal length.
2Reliability
If L-shaped terminals are made longer to reach upper mounting planes, then component connectivity is improved, but terminal material cost increases
Solution Approach 1:
The patent utilizes vertical stacking of mounting planes to reduce terminal length. By arranging planes in the vertical dimension rather than spreading them horizontally, the L-shaped terminals require shorter material lengths to achieve the same connectivity function, directly reducing material costs.
Solution Approach 2:
The patent changes the spatial arrangement parameter from horizontal distribution to vertical stacking. This parameter change transforms the terminal length requirement, allowing the same connectivity to be achieved with shorter terminals by exploiting the vertical dimension for mounting plane arrangement.
3Volume of moving object
If components are stacked vertically in multiple stages, then space utilization is improved, but heat interference between components increases
Solution Approach 1:
The patent stacks mounting planes vertically to improve space utilization. The L-shaped terminals with their horizontal and vertical portions create thermal pathways that dissipate heat in multiple directions, and the stepped arrangement ensures proper thermal spacing between components on different levels, reducing heat interference while maintaining compact vertical stacking.
Data Source
AI summary
An electric connecting structure includes L-shaped terminals having electric connecting portions and a resin member which contains the electric connecting portions. The L-shaped terminals are assembled to a circuit board so that a mounting direction of electric components to the resin member is substantially parallel to an extending direction of the circuit board. The electric components are mounted to the resin member in a plurality of stages which are stacked in a substantially vertical direction with respect to the extending direction of the circuit board. Mounting planes of the resin member in which the electric components are mounted to the resin member are arranged in a step-like shape so as to be displaced backward in the mounting direction by a unit of the stage in accordance with increasing of a distance from the circuit board.