Power Distribution Block Component Position Assurance Element
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Solution Overview
Problem
Existing power distribution blocks fail to provide a secure fit for electrical components, leading to loosening or decoupling due to vibrations and gravitational forces, especially in vehicles and machinery, and existing solutions like foam inserts are difficult to install, expensive, and ineffective in accommodating component variations.
Innovation Solution
A power distribution block design featuring a housing with terminals and a component position assurance element, where the element is fabricated to conform to the collective shape of protruding components, providing a biasing force to prevent disengagement, and can be made from transparent thermoplastic materials using thermoforming, with a cover that applies inward force to maintain components in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If friction fit arrangement and biasing contact device are used to hold electrical components, then components can be secured in place, but components still loosen or decouple due to vibrations and gravitational forces
Solution Approach 1:
A foam insert is introduced as an intermediary element between the electrical components and the housing. The foam insert conforms to the shape of the components and provides continuous contact support, preventing loosening and decoupling caused by vibrations and gravitational forces. The foam material acts as a mediator that distributes mechanical stresses and maintains component positions reliably.
2Stability of the object's composition
If foam inserts are used to secure components, then component position stability improves, but installation difficulty and cost increase
Solution Approach 1:
The foam insert is pre-formed to match the collective shape of multiple electrical components before installation. This preliminary shaping allows the insert to be dropped into the housing as a single piece, automatically conforming to the components it contacts. The pre-formed geometry eliminates the need for complex on-site customization or multiple separate inserts, simplifying installation while maintaining position stability.
3Reliability
If traditional foam inserts are used, then component security improves, but manufacturing cost and complexity increase
Solution Approach 1:
Multiple individual component securing functions are merged into a single foam insert element. Instead of using separate biasing contacts, friction fits, and positioning features for each component, one integrated foam insert provides all necessary securing functions. This merging reduces the number of parts, simplifies the securing mechanism, and lowers manufacturing complexity while maintaining or improving component security.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively secures electrical components within their terminals, preventing decoupling and accommodating variations in size and shape, while being easier to install and more cost-effective than traditional foam inserts, ensuring reliable operation in various orientations.
Implementation Method 1
can be made from transparent thermoplastic materials using thermoforming
Implementation Method 2
providing a biasing force to prevent disengagement
Data Source
AI summary
A power distribution block includes a housing, a plurality of terminals situated in the housing, a plurality of electrical components, each of the electrical components mechanically and electrically engaged to respective terminals, wherein a portion of at least one electrical component protrudes from the housing, and a component position assurance element substantially enclosing the protruding portions of the electrical components.