Vehicle Power Control Unit Connector Guard for Tight Mounting Space
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Solution Overview
Problem
In hybrid and battery electric vehicles, the existing power control units face challenges in secure attachability and protection of connectors in narrow front compartment mount spaces due to increased build and limited space, which affects workability and safety during collisions.
Innovation Solution
An in-vehicle electric device design featuring a connector, fastening portion, and protective wall, where the protective wall is formed integrally with the fastening portion to extend upward and rearward, securely fastening to the vehicle body, and additional protective walls in the case to prevent connector damage during collisions, while maintaining a compact design and reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protectors are fixed via bolts to an exclusive bolt seat extended from the side face of the power control unit, then the connector is protected during collision, but the build of the whole device increases
Solution Approach 1:
The protective wall is integrated into the fastening portion structure, combining the protective function with the fastening function. The protective wall extends upward from the fastening portion and is formed as a single integrated component, eliminating the need for separate protectors and bolt seats while maintaining collision protection capability.
Solution Approach 2:
The protective function is extracted from the fastening portion and extended upward as a dedicated protective wall structure. This allows the protective wall to independently perform collision protection while the fastening portion maintains its fastening function, resolving the space conflict.
2Reliability
If the device build is increased to protect the connector, then the connector protection is improved, but the attachability of the connector in narrow mount space deteriorates
Solution Approach 1:
The protective wall and fastening portion are merged into a single integrated structure, providing protection without increasing the overall device footprint. This maintains the narrow profile required for attachability in constrained mount spaces while delivering collision protection.
3Reliability
If separate protectors and bolt seats are used, then the connector protection is achieved, but the device complexity increases
Solution Approach 1:
The protective wall is formed integrally with the fastening portion, combining what would traditionally be separate components (protectors and bolt seats) into a single molded part. This reduces the number of components, simplifies assembly, and lowers manufacturing complexity while maintaining the protective function.
4Reliability
If additional protective components are added, then the connector protection is improved, but the weight of the device increases
Solution Approach 1:
The protective wall is integrated into the existing fastening portion structure, utilizing the same material and manufacturing process. This eliminates the need for additional protective components and their associated fasteners, thereby avoiding weight increase while maintaining collision protection capability.
Data Source
AI summary
An in-vehicle electric device of this disclosure is provided in a front compartment of a vehicle and includes: at least one electronic component; a case in which the electronic component is accommodated; a connector connected to the electronic component inside the case and projecting rearward from a surface of the case; a fastening portion extended from a lower part of the case and fastened to a vehicle body of the vehicle; and a protective wall formed integrally with the fastening portion such that the protective wall extends upward along a first side face of the connector from the lower part of the case and projects further rearward from a rear end surface of the connector.