Power Control Unit Terminal Block Foreign Object Protection
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Solution Overview
Problem
Conventional power control units for vehicles face challenges in preventing foreign object intrusion while maintaining a reduced size and cost, as existing solutions either increase component count or require additional space for cover attachment, which can lead to increased size and fabrication costs.
Innovation Solution
A power control unit design featuring a terminal block with a first wall extending towards the opening and a rib-like section within the casing, which blocks the path of foreign objects and reduces the unit's size and cost by eliminating the need for additional cover components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a control circuit terminal cover is provided to prevent foreign object intrusion, then foreign object protection is improved, but the number of components increases and fabrication cost rises
Solution Approach 1:
The patent merges the foreign object protection function into the terminal block structure itself by adding a protective wall, eliminating the need for a separate control circuit terminal cover. This integration reduces component count while maintaining protection capability.
Solution Approach 2:
The terminal block is designed to serve multiple functions: electrical connection and foreign object protection. The protective wall structure allows the terminal block to prevent foreign object intrusion while maintaining its primary function of electrical connectivity.
2Reliability
If a control circuit terminal cover is provided to prevent foreign object intrusion, then foreign object protection is improved, but the device size increases due to additional space requirements for cover attachment
Solution Approach 1:
The protective function is merged into the terminal block structure itself, eliminating the need for additional cover attachment space. The protective wall is integrated into the existing terminal block footprint.
Solution Approach 2:
The protective wall extends in the vertical dimension from the terminal block, providing foreign object protection without increasing the horizontal footprint of the device.
Data Source
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AI summary
A power control unit is mounted on a hybrid vehicle, and controls the electric power used for driving the vehicle. The power control unit includes a PCU case (50) having a top cover (51) where an opening (53) is formed, a terminal block (61) placed in the PCU case (50), and arranged opposite to the opening (53), and a substrate (70) placed in the PCU case (50), and on which an electronic component (84) is mounted. The terminal block (61) includes a wall (62). The wall (62) is arranged between the substrate (70) and opening (53), and extends towards the top cover (51) at a circumference of the aperture of the opening (53). By such a configuration, there is provided a power control unit having an intrusion of a foreign object suppressed while accomplishing reduction in size and cost.