Power Supply Casing with Non-Flat Portion for Shock Resistance
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Solution Overview
Problem
Conventional power-supply devices for discharge lamps, when attached to the outside of a lamp housing, face challenges in using press molded metal stamping for the casing due to shock loads, making it difficult to achieve a thin and strong casing structure.
Innovation Solution
A power-supply device with a casing formed by metal stamping, featuring a non-flat portion larger than the external connector's diameter and a cover portion to distribute stress, ensuring the casing's strength and thinness, and a circuit board fixed to the cover portion for enhanced stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a press molded product formed by metal stamping is used for the circuit case, then the casing can be made thinner, but the strength and stiffness required to withstand vehicle shock loads cannot be ensured
Solution Approach 1:
The patent applies local quality by providing a non-flat portion (protrusion or recess) at the specific location where the connector terminal is provided on the circuit case. This localized structural modification increases the moment of inertia and stiffness precisely where the connector terminal experiences shock loads during connector attachment and detachment, while keeping the rest of the casing thin and lightweight.
Solution Approach 2:
The patent transitions from a two-dimensional flat surface to a three-dimensional non-flat structure by adding protrusions or recesses to the circuit case at the connector terminal location. This dimensional change creates a non-flat portion that provides structural reinforcement without significantly increasing the overall casing thickness, thereby achieving both thinness and strength.
2Length of moving object
If the circuit case is made thinner, then the device becomes more compact, but the resistance to deformation under shock loads decreases
Solution Approach 1:
The patent implements local quality by concentrating structural reinforcement at the specific location where the connector terminal is provided, rather than uniformly thickening the entire casing. The non-flat portion (protrusion or recess) creates a localized stiffening effect that maintains overall casing thinness while providing adequate stability at the critical stress point.
3Ease of operation
If a connector terminal is provided on the circuit case for external connector connection, then electrical connection is achieved, but the connector terminal becomes obstructive and vulnerable to shock loads
Solution Approach 1:
The patent converts the harmful shock loads into a beneficial structural feature by designing the non-flat portion (protrusion or recess) to specifically absorb and distribute the impact forces generated during connector attachment and detachment. This transforms the previously harmful shock loads into a means of validating the reinforced structure's effectiveness.
Data Source
AI summary
A power-supply device including a circuit board and a casing which includes a casing portion having an opening, and a cover portion disposed to cover the opening of the casing portion. The casing portion has a through hole formed at a position corresponding to a connector terminal connected to the circuit board, and at least one rib is provided to a region having a size greater than or equal to an outside diameter of a connector of an external connector line connected to the connector terminal in the casing portion.