Power Supply Unit Wall Prevents Dust on Substrates

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Solution Overview

Problem

During the assembly of power supply units with coupled cases, dust and foreign substances can adhere to electronic components mounted on the back side of the upper case, leading to potential malfunctions when the case is turned over, as existing solutions do not effectively prevent contamination.

Innovation Solution

A power supply unit design featuring a wall extending from the top plate of the upper case between the side plate and substrates, which blocks dust and foreign substances from adhering to the substrates during the turning process, ensuring they fall away and do not contaminate the electronic components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the upper case is turned over during assembly to couple it to the lower case, then the coupling efficiency is improved, but dust and foreign substances adhere to the substrates mounted on the back side of the top plate

Engineering Contradiction:

Improvecoupling efficiencyVSAvoiddust adhesion to substrates

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

A wall member is introduced as an intermediary protective structure between the substrates and the external environment. This wall extends from the top plate toward the opening of the upper case, creating a physical barrier that prevents dust and foreign substances from reaching the substrates during the turning and coupling operations, while still allowing the case to be turned over for efficient assembly

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If substrates are mounted on the back side of the top plate for compact arrangement, then the space utilization is improved, but the substrates become exposed to dust when the case is turned over

Engineering Contradiction:

Improvespace utilizationVSAvoidsubstrate exposure to dust

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The protective wall member extends in the vertical dimension from the top plate toward the opening, creating a three-dimensional protective structure. This vertical barrier effectively shields the substrates mounted on the back side of the top plate from dust particles that may settle during the turning operation, while maintaining the compact space utilization achieved by mounting substrates on the back side

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS11462762B2Power supply unit and manufacturing method of the same

Publication Date: 2022.10.04 TOYOTA JIDOSHA KK

AI summary

A fuel cell unit includes a lower case and an upper case. A cell stack of multiple fuel cells is accommodated in the lower case. The upper case is coupled to the lower case. Substrates on which electronic components are implemented are mounted to an inner side of the upper case. A wall extending from a top plate of the upper case is provided between a side plate of the upper case and the substrates. When the upper case is turned, the wall prevents falling dust from adhering to the substrates.