Vehicle Electrical Component Mounting Structure With Scored Hole Seats

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Solution Overview

Problem

Existing methods for attaching electrical components to vehicles result in increased installation man-hours and costs due to the need for covering unused attachment holes, and score processing can weaken the structure by creating notches that concentrate stress, potentially reducing strength.

Innovation Solution

The attachment structure includes first and second attachment seating surfaces with different heights, where the second surface has score processing holes that do not penetrate and are formed at non-attachment positions, dispersing stress and eliminating the need for covers, while allowing necessary holes to be punched out as needed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If score processing is performed to create notches at attachment positions, then attachment holes can be formed as needed, but stress concentration occurs and strength decreases

Engineering Contradiction:

Improveattachment hole formation flexibilityVSAvoidpanel strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The score processing is performed in advance to create notches along the desired hole shape, but the actual punching out is delayed until the attachment is needed. This preliminary scoring allows flexible attachment hole formation while avoiding premature stress concentration from complete penetration holes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of completely punching through the panel at all possible attachment positions, only partial score processing is performed to create notches. The complete hole is only formed when actually needed for attachment, avoiding unnecessary stress concentration in regions where holes are not required.

Inventive Principle:

Principle #16Partial or excessive action

2Adaptability or versatility

If plural attachment holes are formed for multiple vehicle types, then adaptability to different specifications is improved, but installation cost and man-hours increase due to covering unused holes

Engineering Contradiction:

Improvevehicle type compatibilityVSAvoidinstallation efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Multiple score processing holes are created in advance at all possible attachment positions for different vehicle types, but the actual punching out is performed only at the positions needed for each specific vehicle. This eliminates the need to cover unused holes while maintaining adaptability to different vehicle specifications.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The panel is prepared with score processing at multiple potential attachment positions, but the complete hole formation is applied locally only where needed. This allows different attachment configurations for different vehicle types without requiring covers or unnecessary modifications throughout the entire panel.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250206241A1Attachment structure of electrical component and manufacturing method of attachment structure

Publication Date: 2025.06.26 TOYOTA JIDOSHA KK

AI summary

An attachment structure of an electrical component, includes: plural first attachment seating surfaces that are provided at positions at which the electrical component is attached at a vehicle, each of the plural first attachment seating surfaces formed with an attachment hole; and plural second attachment seating surfaces, each of the plural second attachment seating surfaces is formed with a score processing hole on which notch processing has been performed along a shape of a hole to be penetrated, the plural first attachment seating surfaces and the plural second attachment seating surfaces are formed at heights different from a height of other regions.