Power Distribution Line Layout for Compact Relay Units
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Solution Overview
Problem
The existing power distribution devices in relay units tend to increase in size orthogonal to the front surface, which poses a challenge in maintaining a compact design.
Innovation Solution
A power distribution device configuration that includes a switch, control unit, power line, signal line, resin part, and cooling part, where the resin part covers parts of the power and signal lines, and the cooling part is positioned adjacent to the back surface, with laid-out and led-out portions of these lines arranged to minimize the device's size in the planar direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the control bus bar is arranged adjacent to the back surface of the base member and the relay, bus bar, and fan are mounted adjacent to the front surface, then the functional layout is achieved, but the size of the relay unit in the direction orthogonal to the front surface increases
Solution Approach 1:
The patent applies dimensionality change by transitioning from a conventional planar arrangement to a three-dimensional stacked configuration. The control bus bar is positioned on the back surface while the relay, bus bar, and fan are mounted on the front surface, utilizing the thickness dimension of the base member to accommodate multiple functional components without increasing the planar footprint. This vertical stacking approach resolves the contradiction by maintaining functional layout requirements while controlling the overall size in the orthogonal direction.
2Reliability
If components are arranged to achieve proper functional layout, then the device operates correctly, but the planar area occupied by the device increases
Solution Approach 1:
The patent implements nesting by placing the control bus bar and power distribution components within the thickness of the base member structure. The control bus bar is arranged adjacent to the back surface, effectively nesting it within the base member's volume rather than requiring additional planar space. This nested arrangement allows multiple functional components to coexist in a compact configuration, maintaining reliable operation while minimizing the device's planar footprint.
Data Source
AI summary
A power distribution device has a resin part covering a portion of a power line and a portion of a signal line and having a switch adjacent to one surface of the resin part, and a cooling part disposed adjacent to a back surface of the resin part opposite to the one surface. The power line and the signal line each have, inside the resin part, a laid-out portion extending in a planar direction orthogonal to an arrangement direction in which the one surface and the back surface are arranged, and a led-out portion extending from the laid-out portion toward the one surface. The laid-out portion of the power line and the laid-out portion of the signal line are located in a projection area of the cooling unit projected in the arrangement direction, and are separated from each other and arranged in the arrangement direction.