Power Distribution Box Screw Sleeve Torque Isolation
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Solution Overview
Problem
Electrical connectors that use internal busbars often experience solder breakage due to torque transmission from external connections, which compromises the mechanical and electrical integrity of the circuit board connections.
Innovation Solution
A power distribution box design featuring a screw with a rotatable shank and a sleeve that absorbs torque, preventing the transmission of mechanical stress to the soldered areas of the busbar, thereby maintaining the integrity of the electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar is secured to the circuit board by soldering, then the electrical connection is established, but the soldered areas are vulnerable to torque transmission from external connections causing solder breakage
Solution Approach 1:
The patent introduces a screw as an intermediary component between the external connection and the soldered busbar area. The screw provides a mechanical mounting path that bypasses the solder joints, allowing torque from external connections to be absorbed by the screw and housing rather than transmitted to the soldered areas, thus protecting the electrical connection while maintaining mechanical stability
2Strength
If torque is applied at the external connection, then the mechanical connection is secured, but the torque transmission causes solder breakage
Solution Approach 1:
The screw acts as a mediator that decouples the mechanical torque application from the electrical connection. By providing a separate mechanical mounting path through the screw and housing, the torque applied at external connections is absorbed by the mechanical structure rather than transmitted to the soldered electrical joints, thereby maintaining both mechanical strength and electrical reliability
3Stability of the object's composition
If the screw is fixed relative to the circuit board, then the mechanical stability is improved, but the torque transmission to the busbar increases
Solution Approach 1:
The screw serves as a mediator that provides mechanical stability while preventing torque transmission to the busbar. By engaging with the housing rather than the circuit board, the screw creates a stable mechanical mounting path that isolates the busbar and soldered areas from torque stresses, thereby achieving both mechanical stability and reduced stress on electrical connections
Data Source
AI summary
The present disclosure includes a power distribution box comprising a screw defining a longitudinal axis. The screw includes a screw head and a screw shank adjacent to the screw head, the screw shank includes a longitudinal end opposite the screw head. The power distribution box further includes a sleeve comprising an axially extending sleeve hole through which the screw shank extends, a circuit board, and a busbar comprising a busbar hole through which the shank of the screw extends. At least one of the sleeve and the screw is electrically coupled to the busbar, and the busbar is electrically coupled to the circuit board. The screw may be rotatably fixed relative to the circuit board, and the sleeve may be configured to receive a portion of a torque applied to the longitudinal end of the screw shank.