Power Control Unit Terminal Block Wall Integration
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Solution Overview
Problem
Conventional power control units face challenges in preventing foreign object intrusion while maintaining a compact size and low cost, as additional components or cover members required for intrusion prevention increase size and fabrication costs.
Innovation Solution
The power control unit incorporates a wall member integrated with the terminal block, extending from the connector retain hole to the substrate, which suppresses foreign object intrusion without the need for additional cover members or sealing components, thereby reducing size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a cover member is provided to prevent foreign object intrusion into the terminal block, then foreign object intrusion is prevented, but the number of components increases and fabrication cost rises
Solution Approach 1:
The wall member is integrated into the terminal block as a unified structure, eliminating the need for separate cover members. The terminal block and wall member form a single component that provides both electrical connection functionality and foreign object protection, thereby reducing the total number of parts and simplifying assembly processes
2Object-affected harmful factors
If a cover member is provided to prevent foreign object intrusion, then foreign object intrusion is prevented, but the device size increases due to additional space requirements
Solution Approach 1:
The wall member is merged with the terminal block structure, allowing the protection function to be provided within the existing device footprint without requiring additional external space for separate cover members or fixtures
3Object-affected harmful factors
If a cover member is provided to prevent foreign object intrusion, then foreign object intrusion is prevented, but fabrication cost increases
Solution Approach 1:
The terminal block and wall member are formed as a single integrated component, which can be manufactured in one process rather than requiring separate fabrication and assembly steps for multiple parts, thereby reducing manufacturing complexity and cost
Solution Approach 2:
The integrated terminal block-wall member structure serves multiple functions simultaneously: providing electrical connections, offering mechanical support, and preventing foreign object intrusion, which eliminates the need for additional dedicated protection components and reduces overall device cost
Data Source
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AI summary
A power control unit is mounted on a vehicle, and controls the electric power for vehicle-running. The power control unit includes: a PCU case (50) having a lid (51) where an opening (53) is formed; a terminal block (61) having a connector retain hole (110) for retaining an interlock connector (120) formed, and arranged at the PCU case (50), facing the opening (53); and a substrate (70) stored in the PCU case (50), and on which an electronic component (84) is mounted. The substrate (70) is arranged at the side opposite to the lid (51) relative to the terminal block (61), and deviated from the position facing an aperture of the connector retain hole (110). The power control unit includes a wall (130) provided integrally with the terminal block (61), and arranged between the substrate (70) and the connector retain hole (110). By such a configuration, there is provided a power control unit having an intrusion of a foreign object suppressed while aiming to reduce the size and cost.