Power Distribution Box Component Layout Inversion
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Solution Overview
Problem
Conventional power distribution boxes often have inefficient designs due to the arrangement of electrical components being dictated by the wiring harness electrical connector, leading to suboptimal use of circuit board space and increased complexity and cost.
Innovation Solution
A power distribution box assembly with a minimized arrangement of electrical components on the circuit board, where the components are strategically positioned to reduce the number and length of electrical traces, and a corresponding wiring harness connector design that matches this arrangement to minimize trace connections, using a combination of simulation and design optimization techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the arrangement of electrical components on the circuit board is dictated by the wiring harness electrical connector, then the connector can be easily designed, but the circuit board layout becomes inefficient with increased trace length and complexity
Solution Approach 1:
Instead of allowing the wiring harness connector arrangement to dictate the circuit board layout, the patent inverts the design approach by allowing the circuit board layout to dictate the connector arrangement. The electrical components are first optimally positioned on the circuit board to minimize trace length and complexity, and then the wiring harness connector is designed to match this optimized layout, thereby reducing overall system complexity while maintaining manufacturing ease.
2Device complexity
If electrical components are arranged to minimize trace length, then manufacturing complexity and cost are reduced, but the connector design becomes more challenging
Solution Approach 1:
The patent applies preliminary action by first determining the optimal circuit board layout that minimizes trace length and complexity before designing the wiring harness connector. This sequential approach ensures that the connector is designed to match the already-optimized component arrangement, thereby achieving minimal trace complexity while maintaining reasonable manufacturing ease through a structured design process.
3Device complexity
If the wiring harness connector arrangement dictates component placement, then connector design is simplified, but the total amount of electrical traces increases
Solution Approach 1:
The patent inverts the traditional design hierarchy by allowing the circuit board layout to dictate the wiring harness connector arrangement rather than vice versa. This inversion enables the electrical components to be positioned to minimize the total amount of electrical traces required, thereby reducing material usage while the connector is subsequently designed to accommodate this optimized layout.
Data Source
AI summary
A power distribution box assembly may include a housing, a circuit board disposed in the housing, a plurality of electrical components attached to the circuit board, and/or a plurality of electrical traces attached to the circuit board and configured for electrically connecting the plurality of electrical components to at least one of another electrical component of the plurality of electrical components and an electronic control unit. A power distribution box assembly may include a wiring harness connector connected to the housing. In embodiments, a wiring harness connector may include a connector housing and a plurality of connector terminals that may be configured for electrical connection with the plurality of electrical components. A plurality of electrical components may be disposed relative to the circuit board in a manner that minimizes at least one of a number, a length, and a volume of the electrical traces.