Power Distribution Box Integrated Protector Plate
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Solution Overview
Problem
Existing power distribution boxes (PDBs) require a separate protector plate that complicates assembly and does not contribute significantly to structural strength, necessitating additional structural reinforcements and increased weight and thickness.
Innovation Solution
A PDB with a bottom-up construction featuring a frame, a busbar, and a lower cover with an integrated protector plate that forms a unitary structure, eliminating the need for separate assembly and retaining features, and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a separate protector plate is used to protect wires from busbar contact, then wire protection is achieved, but assembly complexity increases and structural strength is insufficient
Solution Approach 1:
The patent integrates the protector plate directly into the lower cover as a single molded piece, eliminating the need for separate assembly of the protector plate. This merging of components resolves the technical contradiction by maintaining wire protection functionality while significantly reducing assembly complexity and eliminating the need for separate retaining features.
2Object-affected harmful factors
If a separate protector plate is used, then wire protection is provided, but additional retaining features are required increasing device complexity
Solution Approach 1:
The protector plate is molded as an integral part of the lower cover, combining two previously separate components into one. This eliminates the need for separate retaining features that would be required to attach a standalone protector plate, thereby reducing device complexity while maintaining wire protection.
3Strength
If the lower cover is constructed with structural reinforcements to meet strength requirements, then structural strength is improved, but weight and thickness increase
Solution Approach 1:
By integrating the protector plate into the lower cover structure, the combined component provides both protection functionality and structural strength. The integrated design allows the lower cover to meet structural strength requirements without adding separate reinforcement elements, thereby avoiding increased weight and thickness.
Solution Approach 2:
The integrated protector plate serves multiple functions: it protects wires from busbar contact and simultaneously contributes to the structural strength of the lower cover. This multi-functionality resolves the contradiction by eliminating the need for separate structural reinforcements that would increase weight and thickness.
Data Source
AI summary
A power distribution box and a method for producing a PDB include molding a lower cover with an integrated protector plate such that a unitary structure is formed. A busbar is inserted into a bottom side of a frame, and a lower cover is attached to the frame from the bottom side, thereby capturing the busbar between the frame and the lower cover. Integrating the protector plate into the lower cover eliminates a molding process, an assembly process, and adds structural integrity to the lower cover without the addition of extra structural support members, thereby reducing material use and the weight of the assembled device.