Modular Power Distribution Box with Interlocking Support Modules
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Solution Overview
Problem
Existing power distribution boxes are often specifically designed for particular automobile makes and models, leading to increased design, manufacturing, and inventory costs due to varying engine compartment space and mounting configurations, limiting their versatility and adaptability.
Innovation Solution
A power distribution box composed of interconnectable support modules with guide rails, grooves, and latch mechanisms that can be assembled in various configurations to form different footprints, allowing for customizable shapes and sizes without the need for a dedicated support frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If power distribution boxes are specifically designed for particular makes and models of automobiles, then they can accommodate specific mounting configurations and space requirements, but design costs, manufacturing costs, and inventory costs increase
Solution Approach 1:
The power distribution box is divided into multiple support modules that can be connected together in different configurations. Each module has interconnectable elements on multiple sides, allowing the system to be segmented into standardized units that can be assembled to fit various vehicle space requirements without designing entirely different boxes for each application.
Solution Approach 2:
The support modules are designed with universal interconnectable elements that can be interconnected in multiple ways to create different footprints and configurations. This multi-functional design allows a single standardized module to serve multiple vehicle makes and models, eliminating the need for application-specific custom designs.
2Adaptability or versatility
If power distribution boxes are specifically designed for particular makes and models of automobiles, then they can fit specific engine compartment spaces, but manufacturing costs and inventory costs increase
Solution Approach 1:
By segmenting the power distribution box into standardized support modules, the manufacturing process is simplified as the same modules can be produced in volume and then assembled into different configurations. This reduces tooling costs, simplifies inventory management, and lowers manufacturing complexity compared to producing custom-designed boxes for each vehicle application.
Solution Approach 2:
The universal support modules can be manufactured using the same processes and tooling for all applications, significantly reducing manufacturing costs and inventory complexity. A single module design serves multiple vehicle makes and models, eliminating the need for multiple specialized production lines.
3Reliability
If a non-conductive body or frame is used to support electrical components, then electrical insulation is provided, but the structure lacks flexibility for different configurations
Solution Approach 1:
The non-conductive support structure is segmented into multiple electrically insulating modules, each capable of being connected to others through interconnectable elements. This segmentation maintains electrical insulation properties while enabling flexible configuration changes by adding, removing, or rearranging modules to match different vehicle space requirements.
Data Source
AI summary
A power distribution box may include a first support module having interconnectable elements provided on a plurality of sides thereof, and a second support module having interconnectable elements provided on a plurality of sides thereof. An interconnectable element on the first support module may be interconnected with an interconnectable element on the second support module to connect the first and second support modules together to form a body of the power distribution box having one of a plurality of possible configurations which define different footprints.