Power Distribution Box Blind Installation Guide Shoulder

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Solution Overview

Problem

The challenge in installing power distribution box assemblies in tight spaces, such as those found in vehicles, where the installation must be conducted blind due to obscured visibility of locking mechanisms, often results in improper alignment and engagement of components.

Innovation Solution

The power distribution box assembly features a rib on its side wall and a guide shoulder on the top cover, providing a tactile response for proper alignment, along with a rear catch and front latch mechanism to ensure secure engagement, even when the locking features are hidden by vehicle structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the power distribution box assembly is installed in tight packaging spaces with obscured visibility, then the installation space utilization is improved, but the alignment precision of locking mechanisms deteriorates

Engineering Contradiction:
Improveinstallation space utilizationVSAvoidalignment precision of locking mechanisms
Core Design Contradiction:
Volume of moving objectVSManufacturing precision

Solution Approach 1:

The patent introduces guide ribs and guide slots as intermediary alignment features between the top cover and power distribution box. These guide structures serve as mediators that provide tactile feedback and physical guidance for proper alignment, resolving the contradiction by enabling precise alignment through intermediate alignment features rather than direct visual inspection of locking mechanisms.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The guide ribs and guide slots provide tactile feedback to the installer during assembly. When the top cover is properly positioned, the guide ribs engage with the guide slots, creating a detectable tactile response that confirms correct alignment. This feedback mechanism allows blind installation with high precision by enabling the installer to sense proper positioning through touch rather than sight.

Inventive Principle:
Principle #23Feedback

2Volume of moving object

If the locking mechanisms are obscured by vehicle structure during installation, then the packaging space efficiency is improved, but the ease of operation deteriorates

Engineering Contradiction:
Improvepackaging space efficiencyVSAvoidease of assembly operation
Core Design Contradiction:
Volume of moving objectVSEase of operation

Solution Approach 1:

The guide ribs and guide slots enable the assembly to be self-aligning during installation. The tactile feedback from the guide structures allows the installer to automatically achieve proper alignment without requiring visual inspection or complex alignment procedures, making the assembly process intuitive and self-correcting even in obscured conditions.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The guide structures act as intermediaries that translate the obscured locking mechanism alignment problem into a tactile guidance system. Rather than requiring direct visual access to hidden locking features, the guide ribs and slots provide an accessible tactile interface that mediates the alignment process, improving ease of operation while maintaining compact packaging.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Manufacturing precision

If visual alignment of locking features is required, then the alignment accuracy is improved, but the device complexity increases due to additional alignment features

Engineering Contradiction:
Improvealignment accuracyVSAvoidcomplexity of alignment features
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies local quality by providing alignment guidance only at specific critical locations where guide ribs and guide slots are positioned. Rather than making the entire assembly complex, the guide features are localized to key alignment points, providing necessary alignment accuracy without uniformly increasing complexity across the entire device.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The alignment function is segmented into distinct guide ribs and guide slots that are separate from the locking mechanisms themselves. This segmentation allows the alignment function to be provided through simple geometric features rather than complex integrated systems, achieving high alignment accuracy while minimizing overall device complexity.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentUS10666031B1Power distribution box assembly with blind installation feature
Publication Date: 2020.05.26 SUMITOMO WIRING SYSTEMS LTD
  • US10666031B1 patent drawing
  • US10666031B1 patent drawing
  • US10666031B1 patent drawing

AI summary

A power distribution box assembly configured to assist in a blind installation is provided. The power distribution box includes a rib disposed on a side wall of the power distribution box. A top cover is configured to close the top of the power distribution box. The top cover includes a guide shoulder disposed on a side wall of the top cover. The guide shoulder extends past a bottom edge of the side wall of the top cover and is configured to be seated over the rib of the power distribution box. Accordingly, the guide shoulder and rib engagement provides a tactile response indicating a proper position of the top cover with respect to the power distribution box.